MTU Detroit Diesel 183 Series Technical Publication
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MTU Detroit Diesel 183 Series Technical Publication

MTU Detroit Diesel 183 Series Technical Publication

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Table of Contents

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Technical Publication
Engine Series 183
Basis: Mercedes--Benz OM 440
Diesel Engine
8V 183 TA.2
8V 183 TC/TE.2/.3
12V 183 TA.2
12V 183 TB/TC.2/.3
12V 183 TD/TE.2/.3
Maintenance Manual
M020080/10E
DaimlerChrysler Off-Highway

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Summary of Contents for MTU Detroit Diesel 183 Series

  • Page 1 Technical Publication Engine Series 183 Basis: Mercedes--Benz OM 440 Diesel Engine 8V 183 TA.2 8V 183 TC/TE.2/.3 12V 183 TA.2 12V 183 TB/TC.2/.3 12V 183 TD/TE.2/.3 Maintenance Manual M020080/10E DaimlerChrysler Off-Highway...
  • Page 2 E 2002 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
  • Page 3 Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us. M020080/10E Postcard MTU Friedrichshafen GmbH Department SCT V 183 T..2/..3 88040 Friedrichshafen...
  • Page 4 Date Name Please mark all filed amendments here. 22.06.99 Please use block capitals! Receipt Amendment No. 22.06.99 Publication number: M020080/10E Name Manufacturer Department Telephone Street Postal box number (Postal code) City Country...
  • Page 5 Group Task Description Subgroup Page General Work Items 20080/1 E 98-12...
  • Page 6 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 7 Group General Subgroup Page General Contents 00-0001 Important information 00-0002 Designation of engine sides and cylinders 00-0003 Tightening Torques 00-0004 Setting values 00-0005 Safety at Work 00-0006 Inspection reports 00-0007 Checking engine condition before W5 overhaul and main overhaul 00-0008 Engine removal 00-0009 Engine running-in...
  • Page 8 Group Subgroup General Page 20080/1 E 98-12...
  • Page 9 Page 00-0001 Important Information This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU Diesel Engine 183 series. This manual describes: − − − − scheduled service operations from maintenance echelons W5 and W6 as well as −...
  • Page 10 − Performance of work by trained personnel − Provision of special tools − Adequate equipping of service area − Use of genuine MTU spare parts General assembly instructions • Component cleanness: Clean the removed parts with cold cleaner or a similar substance and immerse in engine oil SAE 30 to protect against corrosion.
  • Page 11 Group General Subgroup 0001 Page After installing O-rings in shaft grooves, and in order to remedy twists caused by installation, pass a rounded scriber under the sealing ring in the direction of the circumference if the O-ring diameter is sufficiently large. Make sure that the O-ring is not damaged.
  • Page 12 Group Subgroup 0001 General Page a) Threaded connections without tightening specifications For threaded connections without tightening specifications, the tightening procedure can be selected as required, i.e. mechanical tightening with screwdriver or normal manual tightening with an open-end wrench or box wrench is possible. In the event of mechanical tightening, the tightening torque must be taken from the general tightening specifications according to thread size and property class.
  • Page 13 Group General Subgroup 0002 Page 00-0002 Designation of Engine Sides and Cylinders According to Automobile Standard DIN 73021 8 V 183 Engine sides are always designated as viewed from the driving end. The cylinders are designated (as per DIN 73021) as viewed opposite from the driving end, i.e.
  • Page 14 Group Subgroup 0002 General Page 20080/1 E 98-12...
  • Page 15 Group General Subgroup 0003 Page 00-0003 Tightening Specifications for Screws and Nuts Group Designation Engine, Crankcase, Cylinder head Crankshaft bearing cap to crankcase Oil separator to crankcase Oil pan to crankcase Oil drain plug to oil pan Oil filler neck to oil pan Oil dipstick guide pipe union to oil pan Gear case cover and crankcase Drive housing (steering assist pump) to gear case and crankcase...
  • Page 16 Group Subgroup 0003 General Page Group Designation Sealing nut, camshaft bore M22 x 1.5 Friction washer to gear case End cover, compressor opening to gear case Plug, inspection port at start of delivery M26 x 1.5 M38 x 1.5 Cover upper dead center inspection port to gear case Plug, blind hole cylinder head M22 x 1.5 Cylinder head to crankcase Cylinder head cover to cylinder head (flat gasket)
  • Page 17 Group General Subgroup 0003 Page Group Designation Valve gear, valves Rocker shaft support on cylinder head Locknut to adjusting screw for rocker arm Adjusting segment to camshaft gear Fuel system- engine Drive gear to injection pump Injection pump to crankcase Injection pressure lines to injection pump and injection nozzle Securing clamp, injection lines Locknut max-speed seal / idle stop injection pump M6...
  • Page 18 Group Subgroup 0003 General Page Group Designation Air Filter, Exhaust Turbocharger, Charge Air Lines Charge air manifold to cylinder head Charge air lateral pipe to charge air longitudinal pipe Plug to charge air lateral pipe Turbocharger to exhaust elbow Charge air manifold/air intake pipe mounting M8 Exhaust pipes to exhaust elbow and turbocharger Connection of crankcase ventilation to air intake pipe Measuring probe plug...
  • Page 19 Intake pipe to cylinder head Lateral intake pipe to intake pipe Plug to intake pipe M26 x 1.5 Intake air pipe to retainer Start pilot M10 plug MTU Exhaust system(8/12V 183 T..3) Flange to cylinder head Pretighten 30 + 3 Angle of further rotation 60 + 5°...
  • Page 20 Group Subgroup 0003 General Page Group Designation Alternator to carrier M12x1.5 Clamping element bearing cap stud to alternator 40 + 4 Stud to oil pan/carrier Fan belt pulley to alternator M16x1.5 Belt pulley to alternator M27x1.5 Alternator cover Air intake supports to alternator Swivel head alternator to screw M12 74 + 6 Clamping arm to retainer...
  • Page 21 Plug to cover of oil filter M18X1.5 M20x1.5 Oil-filter carrier to crankcase M10 M26x1.5 Oil-filter bowl to oil-filter carrier M12 x 1.5 Oil cooler with flange-mounted, standing oil filter (MTU version) Bulkhead wall to oil-cooler housing M10x25 Oil cooler housing to crankcase M10x25 M10x35 M10x40...
  • Page 22 Group Subgroup 0003 General Page Group Designation Oil cooler cover to oil cooler housing M8x60 M10x35 Oil filter bowl to oil cooler cover M 10x125 M10x60 M10x100 Long-life oil filter Cover to housing Oil supply connection to housing Oil return connection to housing Plug to housing Oil return connection to gear case cover Oil pressure line to turbocharger/crankcase...
  • Page 23 Group General Subgroup 0003 Page Group Designation Belt pulley to coolant pump Raw water pump Impeller clamping nut to drive shaft 32 + 3 Nut M8, bearing housing with intermediate element to pump housing 20 + 2 Plug to pump housing M18X1.5 50 + 10 G1 1/4 A...
  • Page 24 Group Subgroup 0003 General Page Group Designation Engine suspension/Engine mounting Front engine carrier to crankcase Front lifting eye to crankcase Rear lifting eye to gear case Special installations Bearing housing and bearing flange to gear case Drive flange to auxiliary drive shaft Drive gear to shaft Drive flange to bearing housing Oil supply for auxiliary drive (oil nozzle)
  • Page 25 Group General Subgroup 0003 Page Footnotes 1) Crankshaft bearing cap to crankcase Central screws (1) 1. Stage 100 Nm 2. Stage 200 Nm 3. Stage 300 to 330 Nm 4. Stage 90° to 100° angle of rotation Max. shaft length: 156 mm Lateral screws (2) Hex bolts: 80 Nm Double-hex screws...
  • Page 26 Group Subgroup 0003 General Page 3) Connecting rod bearing cap to connecting rod 1. Stage 100 Nm 2. Stage 90° to 100° angle of rotation Max. shaft length: 68.5 mm 4) Drive gear to crankshaft compressor With special tool 442 589 00 03 00, 270 Nm 5) Flywheel / ring-gear carrier to crankshaft 1.
  • Page 27 Group General Subgroup 0003 Page 9) Injection pump to crankcase Double-hex screws in 8V/12V 183 up to 1000 HP Align pump with assembly gauge 422 589 00 63 00 1. Stage 10 Nm 2. Stage 50 Nm 3. Stage 90° to 100° angle of rotation Max.
  • Page 28 Group Subgroup 0003 General Page 20080/1 E 98-12...
  • Page 29 Group General Subgroup 0003 Page Tightening torques in Nm for non-yielding screws with normal nuts and locknuts. (Extract from MBN 10 130 "Tightening torques for screws and nuts with metric threads"). The table values apply to screws and nuts with head dimensions corresponding to MBN 10 105 and MBN 10 143 (without consideration of the torque scatter of the various tightening procedures).The tightening torques are for a friction coefficient range of: = 0.08 - 0.14...
  • Page 30 Group Subgroup 0003 General Page Tightening torques for screws and nuts with metric threads. (Extract from MBN 10 130 "Tightening torques for screws and nuts with metric threads"). The table values apply to screws and nuts with head dimensions corresponding to DIN 912 (without consideration of the torque scatter of the various tightening procedures).The tightening torques are for a coefficient range of: 0.08 - 0.14 Socket head screw...
  • Page 31 Group General Subgroup 0003 Page Tightening torques for set screw- and stud connections according to MTN 5008. #This works standard applies to set screws subjected to little dynamic load as per MMN 384, DIN 912, EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts.
  • Page 32 Group Subgroup 0003 General Page Tightening torques for stress bolt connections according to MTN 5007. This work standard applies to stress pin bolts and stress bolts of strength class 10.9 which are subjected to static and dynamic load, and their associated nuts. Shaft and transition dimensions as to MMN 209 standard and material and machining to MMN 389 (bright surface or phosphate coating).
  • Page 33 Group General Subgroup 0003 Page Tightening torques for plugs according to MTN 5183-1 This works standard applies to plugs as per DIN 908, DIN 910 and DIN 7604 with screwed plug DIN 3852 model A (sealed by sealing ring DIN 7603-Cu). DIN 908 DIN 910 DIN 7604A/C...
  • Page 34 Group Subgroup 0003 General Page Tightening torques for plugs DIN 7604 C (with long screwed plug). Thread Inserted in Steel/grey cast iron Al-alloy (Nm) (Nm) M8 x 1 M22 x 1.5 M26 x 1.5 M30 x 1.5 M38 x 1.5 M45 x 1.5 20080/1 E 98-12...
  • Page 35 Group General Subgroup 0003 Page Tightening torques for banjo screws according to MTN 5183-2 This works standard applies to banjo screws according to MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu MMN 223 (4 flow holes) N 15011 (3 flow holes) Tightening torques M are given for banjo screws made of steel (St) with surface protected by a phosphate coating and oiled or galvanised and for banjo screws made of copper-aluminium alloys.
  • Page 36 Group Subgroup 0003 General Page Tightening torques for male connectors as per MTN 5183-3 This works standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852 model A (sealed by sealing ring DIN 7603-Cu). DIN 2353 Form C Tightening torques M are given for male connectors made of steel (St) with surface protected by a phosphate coating and oiled or galvanised.
  • Page 37 Group General Subgroup 0004 Page 00-0004 Settings Firing order 8V183 : 1 - 5 - 7 - 2 - 6 - 3 - 4 - 8 12V183 : 1- 12 - 5 - 8 - 3 - 10 - 6 - 7 - 2 - 11 - 4 - 9 Direction of rotation viewed from the driving end Crankshaft c.c.w.
  • Page 38 Group Subgroup 0004 General Page Valve stroke at specified valve clearance Engine Inlet Exhaust 12.35 12.30 8V 183 11.95 11.90 12.30 12.25 12V 183 11.90 11.85 20080/1 E 98-12...
  • Page 39 This is especially important for personnel who work only occasionally on the engine. Note: Amendments to this publication will be sent to you provided the receipt card is returned to MTU. This also applies to in-house use by MTU personnel. Spare Parts •...
  • Page 40 • Welding on the engine or engine-mounted components is forbidden. • Never lay the welding cable over or near the cable harnesses of the DB/MTU plants. (The welding current could be induced in the cable harnesses which could possibly damage the electrical plant).
  • Page 41 Group General Subgroup 0005 Page • Use only tools in perfect condition. • Do not work on engines or components which are held only by lifting equipment or crane. Always support them on suitable trestles or stands before beginning any maintenance or repair work. •...
  • Page 42 Group Subgroup 0005 General Page • Do not damage the wiring during removal work. Re-install so that it is not damaged and, during operation, does not come into contact with sharp objects, does not rub against another component or contact a hot surface. Never connect wiring to a line carrying hot liquid.
  • Page 43 Page Fluids and Lubricants, Auxiliary Materials • Use only DB or MTU-tested and approved fuels and lubricants. • Fluids and lubricants must be kept in properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take special care when using hot and caustic materials.
  • Page 44 Group Subgroup 0005 General Page Liquid Nitrogen • Store liquid nitrogen only in small quantities and always in regulation containers (without fixed seal)! • Do not allow liquid nitrogen to come into contact with parts of body (eyes, hands). Liquid nitrogen causes cold burns and severe frostbite.
  • Page 45 Group General Subgroup 0005 Page Warning Notices This publication contains specially emphasised safety instructions starting with signal words graded according to the degree of danger. Take extreme care in these situations! Read and become acquainted with all the warning notices and symbols before operating or repairing this product! Pass on all safety instructions to your operating and maintenance personnel as well! Notice...
  • Page 46 Group Subgroup 0005 General Page 20080/1 E 98-12...
  • Page 47 In order to register the resulting tolerance deviations in good time, the measuring and test equipment must be inspected annually at a location equipped with the appropriate technical facilities. Alternatively, an inspection can be carried out through our Product Support service and DaimlerChrysler/MTU or by an external Product Support service.
  • Page 48 Group Subgroup 0006 General Page 20080/1 E 98-12...
  • Page 49 Deviations from the Engine Acceptance Test Record Data found during the test run provide valuable information for subsequent overhaul services. Instructions for carrying out work: − B = Operating Instructions − P = MTU Test Kit Operations Perform operations preparatory to starting the engine Start engine...
  • Page 50 Group Subgroup 0007 General Page 20080/1 E 98-12...
  • Page 51 Group General Subgroup 0008 Page 00-0008 Engine Removal Instructions for carrying out work − B = Operating Instructions Operations Shut off fuel supply line Shut off compressed air supply Shut off raw water supply line Drain oil with engine warm when possible Drain oil sludge from engine oil filter Oil sludge metallic residue check Drain engine coolant when temperature of coolant is below 60°C...
  • Page 52 Group Subgroup 0008 General Page 20080/1 E 98-12...
  • Page 53 Record the readings for power, fuel, lube oil, coolant, charge air and exhaust at each test point (time, speed and effective power) of the run-in schedule, and enter them under "Engine Run-in" in the MTU Diesel Engine Factory Test" record.
  • Page 54 Check engine for abnormal running noises and leaks Check idle and full-load positions, adjust if necessary. Check oil filter Operation Manual After running-in, perform factory test according to the MTU Engine Acceptance Test Record Enter operational values in the enclosed Factory Test Record MTU Engine Acceptance...
  • Page 55 Group General Subgroup 0009 Page Running-in Schedule 12V183TE à à à à à à à à Engine speed 1280 2190 2750 3196 3525 F (N) à à à à à à à à (rpm) 12 15 17.5 19.3 pe (bar) à...
  • Page 56 Group Subgroup 0009 General Page 20080/1 E 98-12...
  • Page 63 Group General Subgroup 0010 Page 00-0010 Engine Installation and Operation Instructions for carrying out work − B = Operation Manual Tasks Open all connections, remove covers and rubber plugs Attach engine only at the lifting brackets provided as shown in installation drawing, taking centre of gravity and transportation specifications into consideration, and install in plant Join connections appropriately Align engine...
  • Page 64 Group Subgroup 0010 General Page 20080/1 E 98-12...
  • Page 65 Group General Subgroup 0011 Page Group Survey General work items Belt drive, air compressor Engine, Exhaust pipework engine block, cylinder head Electrical motor Running gear Air starting system Valve gear, valves Engine lubrication, engine cooling Fuel system engine Engine cooling Air filter Engine suspension/Engine mounting exhaust turbocharger,...
  • Page 66 Group Subgroup 0011 General Page 20080/1 E 98-12...
  • Page 67 Group General Subgroup 0901 Page 00-0901 Repairing threaded bores with threaded inserts (Heli-Coil) Data Metric thread Blind hole bore dia. Drill 6.31 6.1-6.2-6.25 6.04 8.35 8.1-8.2-8.25-8.3 8.04 8.32 M8 x 1 8.1-8.2-8.25-8.3 8.04 10.40 10.25 10.05 12.50 12.25-12.5 12.05 12.43 M12 x 1.5 12.25 12.05...
  • Page 68 Group Subgroup 0901 General Page Special tools Repair Drill blind hole open with drill Note Do not countersink bore Re-cut damaged thread with special Heli-Coil tapped drill. Mount spindle (1) and mouth piece (2) appropriate to thread on installation tool. Note Groove on mouthpiece (2) must be aligned with markings on installation tool (arrows).
  • Page 69 Group General Subgroup 0901 Page Insert Heli-Coil thread insert (3) into spindle (1) in installation tool. Note Angled end of Heli-Coil thread insert must be in groove (arrow). Use spindle to turn thread insert (3) through mouth piece until it is flush at front. Mount installation tool on threaded hole and install thread insert without applying pressure to spindle.
  • Page 70 Group Subgroup 0901 General Page 20080/1 E 98-12...
  • Page 71 Group General Subgroup 1000 Page 00-1000 Keyword Index Exhaust line removal and installation (V183T..2) 14-3630 Exhaust line removal and installation (V183T..3) 14-3630a Exhaust turbocharger removal and installation (8V/12V 183 T..3) 09-6030a Exhaust turbocharger removal and installation (Engine version with top-mounted turbocharger) 09-6030 Exhaust turbocharger check, examination, fault diagnosis 09-6010...
  • Page 72 Group Subgroup 1000 General Page Injection nozzle with nozzle holder, removal and installation 07-6812 Injection nozzle check 07-6712 Installing and removing injection pump 07-8410 Start of delivery check 07-8234 Guide bearing replacement in flywheel 03-8400 Safety at Work 00-0005 Front Housing Cover Removal and Installation, Radial-Lip Oil Seal Replacement 01-8810 Alternator (generator) removal and installation 15-5030...
  • Page 73 Group General Subgroup 1000 Page Fuel delivery pump(s) check 07-5700 Fuel system diagram 07-0001 Coolant pump removal and installation 20-1290 (Rail and genset versions) Coolant pump removal and installation 20-1290a (Marine version 8/12V 183 T..2/T..3) Coolant pump disassembly and assembly 20-1401 (Rail and genset versions) Coolant pump disassembly, inspection, repair and assembly...
  • Page 74 Group Subgroup 1000 General Page Crankshaft grinding 03-4465 Intercooler removal and installation 09-6810 (Engine version with top-mounted intercooler) Intercooler Removal and Installation 09-6810a (Engine version with compact intercooler) Intercooler leak check 09-6800 Charge air Lines Removal and Installation 09-6812 (Engine version with top-mounted intercooler) Charge air Lines Removal and Installation 09-6812a (Engine version with compact intercooler)
  • Page 75 Group General Subgroup 1000 Page Oil filter element removal and installation 18-3476 Oil cooler removal and installation (hanging oil filter) 18-6840 Oil cooler disassembly and assembly (flange-mounted, standing oil filter) 18-7109a Oil cooler disassembly and assembly (hanging oil filter) 18-7109 Oil lines 18-1600 Oil pump removal and installation...
  • Page 76 Group Subgroup 1000 General Page Flywheel removal and installation 03-8001 Flywheel machining 03-8042 Seawater pump removal and installation 20-1390 (Marine version 8/12V 183 T..2 with top-mounted intercooler) Seawater pump removal and installation 20-1390a (Marine version 8/12V 183 T..2/T..3 with compact intercooler) Seawater pump disassembly, inspection, repair and assembly 20-1402 (Marine version 8/12V 183 T..2 with top-mounted intercooler)
  • Page 77 Group General Subgroup 1000 Page Valve seat insert replacement 05-3832 Valve clearance adjustment 05-1122 Compressor disassembly and assembly 13-7001 Compression pressure check 01-1205 Coolant heat exchanger (plate core) with "SWEP": Plate removal, disassembly, inspection, repair 20-2570b and installation (Marine version 8/12V 183 T..2/T..3 with compact intercooler) Coolant heat exchanger (plate core) with "GEA": Plate removal, inspection, repair and installation 20-2570 (Marine version 8V 183 T..2 with top-mounted intercooler)
  • Page 78 Group Subgroup 1000 General Page 20080/1 E 98-12...
  • Page 79 Group Task Description Subgroup Page Engine, Crankcase, Cylinder head 20080/1 E 98-12...
  • Page 80 Group Subgroup Task Description Seite 20080/1 E 98-12...

  • Page 81: Table Of Contents

    Group Task Description Page Engine, Crankcase, Cylinder head Contents 01-1205 Compression pressure check 01-5014 Cylinder head cover removal and installation 01-6110 Cylinder head removal and installation 01-7162 Cylinder head plane machining 01-7500 Oil pan removal and installation 01-8000 Gear case cover removal and installation 01-8205 Gear case removal and installation 01-8810...
  • Page 82 Group Subgroup General Page 20080/1 E 98-12...

  • Page 83: Compression Pressure Check

    Group Task Description Subgroup 1205 Page 01-1205 Compression Pressure Check Preparatory operations Valve clearance adjusted (05-1122). Leave engine at operating temperature (70°C - 95°C). Injection Nozzle with Nozzle Holder, Removal and Installation (07-6812). Data Compression pressure min. 17 bar Pressure difference in individual cylinders max.
  • Page 84 Group Subgroup 1205 General Page Note If the compression pressure is less than 17 bar or the pressure difference between individual cylinders is greater than 4 bar, remove the cylinder heads in order to check the valve seats and cylinder bores. Remove compression pressure recorder and connector.

  • Page 85: Cylinder Head Cover Removal And Installation

    Group Task Description Subgroup 5014 Page 01-5014 Cylinder Head Cover Removal and Installation 1 Hex bolt 25 Nm 2 Spring washer 3 Cylinder head cover 4 Gasket Removal/installation Remove hexagon bolts (1), lift off cylinder head cover (3) and gasket (4). Note on installation Clean cylinder head cover and sealing face on cylinder head.
  • Page 86 Group Subgroup 5014 Task Description Page 20080/0 E 97-02...

  • Page 87: Cylinder Head Removal And Installation

    Group Task Description Subgroup 6110 Page 01-6110 Cylinder Head, Removal and Installation Preparatory operations: Engine coolant drained Intake manifold removed (14-1421). Exhaust manifold removed (14-0068). Cylinder head cover removed (01-5014). 1 Rocker arm screw 75 Nm 2 Rocker arms 3 Cylinder head screw Socket wrench insert 422 589 00 09 00, Reusable up to max.
  • Page 88 Group Subgroup 6110 Task Description Page Tightening torques Injection line on pump and nozzle Intake elbow Cylinder head cover Exhaust elbow Rocker shaft support on cylinder head Arrangement of injection lines 8 V 183 12 V 183 Special tools 20080/1 E 98-12...
  • Page 89 Group Task Description Subgroup 6110 Page Removal Unscrew union nut for injection lines on nozzle holder. Box wrench 000 589 07 03 00 Unscrew union nuts of the injection lines on the injection pump. Hold pipe connection firmly in position. Note Do not bend injection line.
  • Page 90 Group Subgroup 6110 Task Description Page Remove cylinder head screws (3 and 4). Socket wrench insert 422 589 00 09 00 Remove cylinder head screw (5) under the nozzle holder. Note If the nozzle holder is still installed, the cylinder head screw (5) cannot be removed.
  • Page 91 Group Task Description Subgroup 6110 Page Installation Clean threaded bores in crankcase. Clean cylinder head partitions and crankcase end surface. Place the new cylinder head gasket over the centring sleeves (8) onto the cylinder crankcase end surface. Note With replacement engines, the cylinder crankcase partitions and bush collar seat are machined if necessary.
  • Page 92 Group Subgroup 6110 Task Description Page Slightly lubricate cylinder head screws, screw in and tighten using socket wrench insert 422 589 00 09 00 in the specified sequence in the following stages: 1. Stage 10 Nm 2. Stage 50 Nm 3.
  • Page 93 Group Task Description Subgroup 6110 Page Install injection lines (10) install and secure to nozzle holder and injection pump, 25 Nm. Box wrench insert 000 589 68 03 00. Note Hold injection pump thrust nut firmly in position Serrated wrench 000 589 50 03 00, Box wrench insert 000 589 68 03 00.
  • Page 94 Group Subgroup 6110 Task Description Page 20080/1 E 98-12...
  • Page 95 Group Task Description Subgroup 7162 Page 01-7162 Cylinder Head Reconditioning Preparatory operations: Cylinder head removed (01-6110). Valves removed (05-4102). Injection nozzle removed (07-6812). Check cylinder head support surface for flatness and indentations with straight-edge or bridge meter. Cylinder heads with worn support surfaces can be reconditoned with a grinding machine. Stop reconditioning as soon as the specified surface is reached, refer here to the Tolerance and Wear Limits List.
  • Page 96 Group Subgroup 7162 Task Description Page 20080/1 E 98-12...

  • Page 97: Oil Pan Removal And Installation

    Group Task Description Subgroup 7500 Page 01- 7500 Oil Pan, Removal and Installation 1 Gasket 2 Gasket Replace. 3 Oil pan 4 Washer 5 Hex bolt Corner hex bolts, 35 Nm. Remaining hexagon bolts 35 Nm. Follow tightening diagram. 6 Oil drain plug 80 Nm.
  • Page 98 Group Subgroup 7500 Task Description Page 1 Gasket 2 Gasket Replace. 3 Oil pan 4 Hex nut Corner hex nuts 35 Nm. Remaining hexagon nuts 35 Nm. Follow tightening diagram. 5 Washer 6 Stud 7 Oil drain plug 80 Nm. 8 Gasket Replace.
  • Page 99 35 Nm (starting with the last tightened corner screw). Tighten corner hex bolts and nuts, 35 Nm. Fill with oil according to MTU Fluids and Lubricants Specification Start the engine and observe the oil-pressure indicator at idling speed. After approx. 10 seconds the oil- pressure gauge must indicate oil pressure.
  • Page 100 Group Subgroup 7500 Task Description Page 20080/1 E 98-12...

  • Page 101: Gear Case Cover Removal And Installation

    Group Task Description Subgroup 8000 Page 01- 8000 Gear Case Cover Removal and Installation 1 Gear case cover Assembly bracket 403 589 05 63 00. 2 Gasket Replace, spray gun 000 589 01 25 00. Notes Up to engine end No. 473 000, the gear case cover gasket can only be replaced together with the injection pump sealing ring.
  • Page 102 Group Subgroup 8000 Task Description Page Sealing Remove the attachments (depending on engine type), lines, fuel filter, on gear case cover. Remove gear case cover (1) and sealing ring. Clean gear case cover and insert new sealing ring (2). Note Beginning engine end No.
  • Page 103 Group Task Description Subgroup 8000 Page Seal the partition surface between cylinder crankcase and gear case, right and left, with silicone sealing agent. Spray gun 000 589 01 25 00 Mount the gear case cover and secure with assembly bracket (arrow). Assembly bracket 403 589 05 63 00 Tighten the hex bolts in the specified sequence to 25 20080/0 E 97-02...
  • Page 104 Group Subgroup 8000 Task Description Page 20080/0 E 97-02...

  • Page 105: Gear Case Removal And Installation

    Group Task Description Subgroup 8205 Page 01-8205 Gear Case, Removal and Installation Preparatory operations: Engine removed Gear case cover removed (01-8000). Flywheel removed (03-8003). 1 Gear case Spray gun 000 589 01 00, seal partition surface between cylinder crankcase and oil pan with silicone sealing agent.
  • Page 106 Group Subgroup 8205 Task Description Page Special tools Removal Remove intercooler (depending on engine model) Remove turbocharger (09-6030) if necessary. Remove starter from gear case. Release all hex bolts (9) and bolts and lower oil pan. Note Do not damage oil pan seal. Unscrew double hex bolts (6) and hex bolt (7) and lift off the gear case.
  • Page 107 Group Task Description Subgroup 8205 Page Installation Clean gear case and sealing face on cylinder crankcase. Mount the new gasket via the guide pins on cylinder crankcase and adjust to correct length (arrow). Seal partition surfaces between gear case gasket and oil pan gasket with silicone sealing agent.
  • Page 108 Group Subgroup 8205 Task Description Page Mount the oil pan and tighten hex bolts and nuts. − Tighten the corner hex bolts and nuts diagonally and evenly A-C and B-D, 35 Nm. − Tighten hex bolts and nuts in sequence around the circumference to 35 Nm (starting from the last tightened corner hex bolt or nut).
  • Page 109 Group Task Description Subgroup 8810 Page 01-8810 Front Housing Cover, Removal and Installation, Radial-Lip Oil Seal Replacement Preparatory operation: Vibration damper and hub, removed (03-1600). 1 Injection ring 2 Radial-lip oil seal Replace, mandrel 312 589 13 15 00. 3 Housing cover 4 Hex screws 25 Nm.
  • Page 110 Group Subgroup 8810 Task Description Page Removal Remove injection ring (1). Release oil pan hex bolts and nuts and lower the oil pan. Unscrew front hex bolts and nuts (8) for the oil pan and housing cover. Unscrew the hex bolts (4) around the circumference of the housing cover and remove the housing cover with radial-lip oil seal.
  • Page 111 Group Task Description Subgroup 8810 Page Remove the radial-lip oil seal (2) from the cover. Note Support the cover when removing the radial-lip oil seal . Mandrel 312 589 13 15 00 Installation Place the housing cover flatly on an even surface and install radial-lip oil seal flush to the surface.
  • Page 112 Group Subgroup 8810 Task Description Page Install oil pan. Note Check gasket for damage. Tighten hex bolts and nuts on oil pan. − Tighten corner hex bolts and nuts diagonally A-C and D, 35 Nm. − Tighten hex bolts and nuts in sequence around the circumference to 35 Nm (beginning at the last tightened corner hex bolt or nut).
  • Page 113 Group Task Description Subgroup 8825 Page 01-8825 Replacing Track Ring on Crankshaft Preparatory operation: Front of housing cover removed (01-8810). 1 Track ring Removal tool 442 589 00 33 00, Installation temperature approx. 200°C, Mandrel 403 589 06 15 00. Special tools 20080/1 E 98-12...
  • Page 114 Group Subgroup 8825 Task Description Page Track ring replacement Place the removal tool via the track ring on the crankshaft and tighten the hex bolts (arrows). Note Track ring with a dust collar: Press off dust collar . Pull off track ring. Removal tool 442 589 00 33 00, Heat new track ring to approx.

  • Page 115: Removal Of Corroded Sections On Cylinder Crankcase Surfaces

    Group Task Description Subgroup 9112 Page 01-9112 Removal of Corroded Sections on Cylinder Crankcase Surfaces Preparatory operation: Cylinder head removed (01-6110). Machine surfaces Note If the corrosion is in the immediate area of the cylinder liner collar, the piston and cylinder liners should be removed.
  • Page 116 Group Subgroup 9112 Task Description Page File surface of the section to be machined (arrow) with a finishing file. Clean partition surface and remove covers from cylinder bores and oil channels. 20080/1 E 98-12...
  • Page 117 Group Task Description Subgroup 9304 Page 01-9304 Reconditioning Liner Collar Seat Preparatory operation: Cylinder liners removed (01-9324). Special tools Equipment Liner collar seat - machining device Cylinder crankcase reconditioning Cover crankshaft, shaft journals, oil bores and cylinder bores. Clean partition surface on cylinder crankcase and cylinder liner support.
  • Page 118 Group Subgroup 9304 Task Description Page • Tombak ring thickness: 0.15 ± 0.01 Note 0.30 ± 0.01 After the collar seat has been machined, different 0.50 ± 0.01 thicknesses of Tombak rings are permitted for sealing. • Support ring thickness: 0.80 ± 0.01 1.00 ±...
  • Page 119 Group Task Description Subgroup 9304 Page Pull fast adjusting ring (2) in the direction of the turning crank and insert turning chisel (1). Insert the turning chisel so that the centring roller (arrow) comes to rest in the middle of the side of the turning chisel support which is marked with an "R".
  • Page 120 Group Subgroup 9304 Task Description Page Lift up the fast adjusting ring (2) and push the turning chisel (1) through until the centring roller lies against the side wall (arrow) of the liner collar. Bring the toggle switch (3) to middle position (middle position "0").
  • Page 121 Group Task Description Subgroup 9304 Page After centering, press toggle switch (3) to position "1". Lift up fast adjusting ring (2) and push the turning chisel (1) through until the cutter lies above the section of the bush collar seat which has to be machined (but not against the side wall).
  • Page 122 Group Subgroup 9304 Task Description Page Turn over driving crank (4) evenly in a clockwise direction while holding the face feed ring (7). Note The advance nut (5) must remain firmly in position. Turn over driving crank (4) until the turning chisel reaches the cylinder bore outer diameter.
  • Page 123 Group Task Description Subgroup 9304 Page Position dial gauge feeler (arrow) on partition on cylinder crankcase and read off balcony depth. B Turning device without measuring point Remove the machine approx. 0.3 mm before reaching the determined balcony depth and measure the balcony depth again with the dial gauge to ensure that the desired final dimension has also been reached.
  • Page 124 Group Subgroup 9304 Task Description Page Re-measure balcony depth. The difference between the 4 measuring point must be no more than 0.02 mm. Dial gauge 001 589 53 21 00 Dial gauge holder 343 589 00 40 00 Using a flat scraper, break the upper edge of the upper lining fit approx.
  • Page 125 Group Task Description Subgroup 9314 Page 01-9314 Measuring Cylinder Liner Protrusion Preparatory operation: Cylinder head removed (01-6110). Special tools Measurement Clean cylinder liner collar. Place measuring plate on cylinder liner. Tighten short cylinder head screws with spacer sleeve (1) to 50 Nm. Measuring plate 402 589 00 21 00 Mount dial gauge holder (C) on measuring plate and...
  • Page 126 Group Subgroup 9314 Task Description Page Note At every measuring point set the dial gauge scale on the partition surface to "0". Maximum difference between 4 measuring points, per liner, is 0.02 mm. The cylinder heads of the neighbouring cylinders must be removed in order to measure the cylinder lining protrusion .
  • Page 127 Group Task Description Subgroup 9324 Page 01-9324 Cylinder Liner Removal, Inspection, Repair, Installation and Sealing Preparatory operation: Piston removed (03-7004). Special tools Note The seal between liner and crankcase has been changed to a tombac sealing ring (1). The sealing ring and sealant in the fillet (2) has been omitted.
  • Page 128 Group Subgroup 9324 Task Description Page Removal Mark the cylinder liners to the crankcase (arrow). Note: Before operating the liner removal tool, check the spacer sleeve (4) and, if necessary, shorten to a level of 175 mm. Insert stud screws (5) in opposite threaded bores for cylinder head screws.
  • Page 129 Group Task Description Subgroup 9324 Page Inspection and repair Check liner for cracks and cavitation Clean liner and test with magnetic particle inspection and fluorescent magnetic-powder penetration methods for cracks (3). Replace liner if cracks are found. Check outer wall for cavitiation (2) and corrosion, replace liner if necessary.
  • Page 130 Group Subgroup 9324 Task Description Page If liners are to be re-used, the hone pattern over the total surface must be more or less quite recognizable. Individual light scorings when extracting are not critical. No signs of wear should be felt at the return stroke position of the first piston ring.
  • Page 131 Group Task Description Subgroup 9324 Page Installation and Sealing If new liners are to be installed, they should be assigned together with the pistons according to the tolerance- group coding. The tolerance-group coding (arrow) is given on the top liner surface and the piston crown. Code: Cylinder liner Þ...
  • Page 132 Group Subgroup 9324 Task Description Page Coat sealing agent (bead of approx. 2-3 mm dia) in front of the sealing ring on lining collar. Note Work with the sealing agent in viscous form only . Spray gun 000 589 01 25 00 Apply thin coat of ATE assembly grease to exterior of cylinder liner at lower fit surface and chamfer.

  • Page 133: Measure Cylinder Liner Protrusion

    Group Task Description Subgroup 9324 Page Lift the installation tool off the cylinder crankcase. Using a plastic spatula, carefully remove the sealing agent (arrow) that is forced out between the crankcase and cylinder liner when the cylinder liner is being pretensioned.
  • Page 134 Group Subgroup 9324 Task Description Page B Sealing with a tombac ring Insert new, dry O-rings for the lower cylinder lining sealing in the cylinder crankcase. Place the tombac ring (1) via the cylinder liner on the cylinder liner collar. Insert new O-ring (3) for the upper cylinder liner sealing in the cleaned recesses of the lining.
  • Page 135 Group Task Description Subgroup 9324 Page Insert stud screws for the extractor and installation tool in the threaded bores for the cylinder head screws opposite. Place the pressure plate (arrow) on the cylinder liner. Place the extractor (spindle with counter support) on stud screws and tighten.
  • Page 136 Group Subgroup 9324 Task Description Page 20080/1 E 98-12...

  • Page 137: Repairing Engine Pto

    Group Task Description Subgroup 9444 Page 01- 9444 Repairing Engine PTO Preparatory operations: Universal shaft removed. Gear case cover removed (01-8000). 1 Gear case 2 O-Ring Replace 3 Housing bush Counter support 000 589 35 33 00, Internal extractor 000 589 68 33 00. Oil.
  • Page 138 Group Subgroup 9444 Task Description Page Special tools Disassembly Unscrew securing nut (20) for drive gear (19). 20080/1 E 98-12...
  • Page 139 Group Task Description Subgroup 9444 Page Unscrew securing nut (18). Lift off drive flange (17) and cover plate (16). Unscrew hex bolts (15), lift off bearing cover (12). Remove O-ring (11) and shim (10). Secure extractor with securing nut (18). Extractor 354 589 00 33 00 Pull out shaft (5) with bearings.
  • Page 140 Group Subgroup 9444 Task Description Page Push both bearings (7, 8) and track ring (9) on the driving end from the shaft. Pull the inner bearing race (4a) for the driving end roller bearing from the shaft. Extractor 001 589 19 33 00 Press the roller bearing (4) on the driving end side from the housing bush.
  • Page 141 Group Task Description Subgroup 9444 Page Assembly Mount the O-ring (2) above the housing bush (3). Drive rear (wide) roller bearing (4) into housing bush (3). Oil bearing. Place the housing bush (3) in the gear case with the machined surface facing the gear case cover. 20080/1 E 98-12...
  • Page 142 Group Subgroup 9444 Task Description Page Heat gear case with a hot air blower and drive the housing bush (3) into the gear case. Heat the inner race for rear bearing (4) on a heating plate to approx. 80°C and - on the drive side - mount on the shaft (5).
  • Page 143 Group Task Description Subgroup 9444 Page Heat the inner race for roller bearing - PTO side - to approx. 80°C and mount on the shaft (5). Notice! Risk of injury! Mount the roller bearing (8) on the inner bearing race. Heat the track ring (9) for the shaft seal to approx.
  • Page 144 Group Subgroup 9444 Task Description Page Mount the shaft seal (13) and sealing ring (11) in the bearing flange (12). Mount the shim (10). Mount bearing cover (12) and tighten hex bolts (15) diagonally to 10 Nm. Using a feeler gauge, determine the distance between bearing cover and housing bush.
  • Page 145 Group Task Description Subgroup 9444 Page Mount PTO flange (17). Tighten new securing nuts to 300 Nm and secure. Retaining wrench 460 589 01 31 00 Box wrench 402 589 03 03 00. Note Hold PTO flange firmly in position. Tighten securing nut (20) for drive gear (19) to 300 Nm.
  • Page 146 Group Subgroup 9444 Task Description Page 20080/1 E 98-12...

  • Page 147: Oil Separator Check, Removal And Installation

    Group Task Description Subgroup 9751 Page 01-9751 Oil Separator, Checking, Removal and Installation Preparatory operations: Oil level checked and corrected. Engine at operating temperature. 1 Clamp 8 Nm. 2 O-Ring Replace. 3 Oil separator Control range: + 10 to - 100 mm water column 4 Clamp 5 Tube Tool for customer production...
  • Page 148 Group Subgroup 9751 Task Description Page Checking Connect the corresponding long end of the water- pressure gauge with the oil dipstick guide pipe and fill the water-pressure gauge up to the "zero mark" with water. Start the engine and observe the water level in pressure gauge.
  • Page 149 Group Task Description Subgroup 9751 Page There is a vacuum in the cylinder crankcase if the water column at the connected end of the tube (right) is higher than at the free end (left) - (maximum - 100 mm water column). The correct level is indicated as the difference between the two water surfaces.
  • Page 150 Group Subgroup 9751 Task Description Page Removal, installation Disconnect water-pressure gauge tube at the oil dipstick guide pipe, insert oil dipstick. Remove charge air manifold (09-8621). Release clamp (4) and pull off tube (5) at oil separator (3). Release clamp (1) and lift oil separator (3) off cylinder crankcase.
  • Page 151 Group Task Description Subgroup Page Running Gear 20080/1 E 98-12...
  • Page 152 Group Subgroup Task Description Seite 20080/1 E 98-12...
  • Page 153 Group Task Description Subgroup Page Running gear Contents 03-1300 Crankshaft belt pulley removal and installation 03-1600 Vibration Damper and Hub, Removal and Installation 03-1600a Vibration Damper , Removal and Installation (8/12V 183 T..3) 03-3062 Gear Case Radial-Lip Oil Seal Replacement 03-3203 Track ring on Flywheel, Replacement 03-4352...
  • Page 154 Group Subgroup Task Description Seite 20080/1 E 98-12...

  • Page 155: Crankshaft Belt Pulley Removal And Installation

    Group Task Description Subgroup 1300 Page 03-1300 Crankshaft belt pulley removal and installation Belt pulley Belt pulley Spring washer Hex bolt Tightening torque: 21 + 2 Nm. Lubrication: Engine oil Set of V-belts Removal and installation See diagram. 20080/0 E 98-04...
  • Page 156 Group Subgroup 1300 Task Description Page 20080/0 E 98-04...

  • Page 157: Vibration Damper And Hub, Removal And Installation

    Group Task Description Subgroup 1600 Page 03-1600 Vibration Damper and Hub, Removal and Installation 1 Hex nut 25 Nm. 2 Stud 3 Hex bolt 25 Nm. 4 Spring washer 5 Intermediate element 6 Belt pulley 7 Hex screws 200 Nm. 8 Vibration damper (one-part) 9 Hub 10 Injection ring...
  • Page 158 Group Subgroup 1600 Task Description Page Removal, installation Remove drive belt. Remove fan with intermediate element and belt pulley.* * Only for engines with fan cooler. Unscrew hex bolts (7) and remove vibration damper. Installation instructions Tighten hex bolts (7) to 200 Nm. Install in reverse order.

  • Page 159: 03-1600A Vibration Damper , Removal And Installation (8/12V 183 T

    Group Task Description Subgroup 1600a Page 03-1600a Vibration Damper, Removal and Installation(8 / 12V183...3) Vibration damper Cover plate Hex bolt 200 Nm. Timing pointer 20080/1 E 98-12...
  • Page 160 Group Subgroup 1600a Task Description Page Removal and installation Remove drive belt. Unscrew hex bolts (7) and remove vibration damper. Installation instructions: The position of the vibration damper to the crankshaft should be marked during initial assembly as shown in the drawing 506 005 00 01.

  • Page 161: Gear Case Radial-Lip Oil Seal Replacement

    Group Task Description Subgroup 3062 Page 03-3062 Gear Case Radial-Lip Oil Seal Replacement Preparatory operation: Flywheel removed (03-8001). 1 Radial-lip oil seal Replace. Mandrel 403 589 04 15 00. Special tool 20080/0 E 97-02...
  • Page 162 Group Subgroup 3062 Task Description Page Replacement Using suitable tool, remove radial-lip oil seal (1) from gear case. Note Do not damage gear case and crankshaft. Fit spacer sleeve (arrow) of mandrel 403 589 04 15 00 on crankshaft. Mandrel 403 589 04 15 00 Fit radial-lip oil seal on mandrel and install into gear case.

  • Page 163: Track Ring On Flywheel, Replacement

    Group Task Description Subgroup 3203 Page 03-3203 Track Ring on Flywheel, Replacement Preparatory operation: Flywheel removed (03-8001). 1 Track ring Thrust pad 312 589 00 15 00. 2 Flywheel Mandrel 403 589 03 15 00. Puller 000 589 45 33 00. Special tools 20080/1 E 98-12...
  • Page 164 Group Subgroup 3203 Task Description Page Replacement Remove track ring (1) with puller and thrust pad (3) from flywheel. Removal tool 000 589 45 33 00. Thrust pad 312 589 00 15 00. Fit new track ring with rounded edge in direction of mandrel and heat to max.

  • Page 165: Crankshaft Removal, Storage, Installation

    Group Task Description Subgroup 4352 Page 03- 4352 Crankshaft Removal, Storage and Installation Preparatory operations: Gear case removed (01-8205). Front housing cover removed (01-8810). Vibration damper removed (03-1600). Piston removed (03-7004). Flywheel removed (03-8001). Oil filter carrier removed. Crankshaft bearing cap screws (centre) Re-usable until shaft length max.
  • Page 166 Group Subgroup 4352 Task Description Page Special tools Removal Withdraw hex bolts (9) and remove front housing cover (10) and gasket. Mark crankshaft bearing cap and crankshaft bearing in sequence with respect to one another. Remove all screws (1 and 2) and remove crankshaft bearing cap.
  • Page 167 Group Task Description Subgroup 4352 Page Insert a guide mandrel (arrows) at both the top and bottom crankshaft ends and remove crankshaft. Guide mandrel 403 589 02 63 00. Remove bearing shell halves from crankcase and allocate to respective crankshaft bearing caps. Check components for wear and damage.
  • Page 168 Group Subgroup 4352 Task Description Page Measure shaft length of centre crankshaft bearing cap screws (1) (max. reusability up to 156 mm). Tighten centre crankshaft bearing cap screws (1) in the following stages: 1. Stage 100 Nm 2. Stage 200 Nm 3.
  • Page 169 Group Task Description Subgroup 4352 Page Measure crankshaft bearing bore with bore gauge at three points (vertical and at a distance of 30° above and below the partition). Dial gauge 001 589 53 21 00 Note The values given in the Tolerance and Wear Limits List (03-4352) must be kept to.
  • Page 170 Group Subgroup 4352 Task Description Page Check hardness of crankshaft with hardness tester. Note Conversion table is supplied with hardness tester. Hardness tester 000 589 20 21 00 The values given in the Tolerance and Wear Limits List (03-4352) must be kept to. Insert bearing shell halves in correct sequence into crankcase and crankshaft bearing cap and lubricate.
  • Page 171 Group Task Description Subgroup 4352 Page Markings (arrows) on camshaft gear and crankshaft gear must be aligned. Install marked crankshaft bearing cap (arrow) with bearing shells into crankcase. Measure shaft lengths of centre crankshaft bearing cap screws (1) (max. reusability up to 156 mm) and tighten in the following stages: 1.
  • Page 172 Group Subgroup 4352 Task Description Page Install dial gauge holder with dial gauge on crankcase and check axial clearance (0.150 to 0.322 mm) of crankshaft. Dial gauge 001 589 53 21 00 Dial gauge holder 363 589 02 21 00 Fit new gasket over guide pins on cylinder crankcase.

  • Page 173: Crankshaft Grinding

    Group Task Description Subgroup 4465 Page 03- 4465 Crankshaft Grinding Preparatory operation: Crankshaft removed (03-4352). Tightening torques 1. Stage 140 to 160 Nm Counterweight on crankshaft 2. Stage 90° to 100° angle of rotation Shaft length of counterweight screws Up to engine end No. 517 Max.
  • Page 174 Group Subgroup 4465 Task Description Page Check crankshaft hardness: Refer to the Tolerance and Wear Limits List 03-4352. Hardness tester 000 589 20 21 00 Centre crankshaft prior to grinding (support crankshaft at 1st and last main bearing journal). When machining, regrind all bearings to the next dimension.
  • Page 175 Group Task Description Subgroup 4465 Page Note Install counterweights according to markings Fit counterweight (1) on crankshaft and tighten slightly with hexagonal socket-head screw (2). Note Do not fully tighten hexagonal socket-head screw (2). Position V-block (3) on respective main bearing cap so that lug (arrow) is between counterweight (1) and main bearing cap.
  • Page 176 Group Subgroup 4465 Task Description Page 20080/1 E 98-12...
  • Page 177 Group Task Description Subgroup 6312 Page 03-6312 Conrod Storage Preparatory operation: Piston removed (03-7004). 1 Conrod bearing shell 2 Conrod with cap 3 Conrod bushing 4 Conrod bolt Re-usable until shaft length max. 68.5 mm, Tightening torques: 1. Stage 100 Nm, 2.
  • Page 178 Group Subgroup 6312 Task Description Page Special tool Equipment Bore gauge 50 - 100 mm Micrometer 75 - 100 mm Storage Note: Conrod bearing shells are ready for installation when supplied. No reconditioning can be carried out. Bearing shell halves with dark reverse side must be installed on the rod side because they are specially treated for high pressures.
  • Page 179 Group Task Description Subgroup 6312 Page Tighten conrod bearing screws (4) in the following stages: 1. Stage 100 Nm 2. Stage 90° to 100° angle of rotation Note Secure conrod just below conrod bearing to prevent conrod from twisting. Set bore gauge 50 - 100 mm dia. and dial gauge with micrometer 75 - 100 mm to zero dimension of conrod bearing bore.
  • Page 180 Group Subgroup 6312 Task Description Page 20080/1 E 98-12...
  • Page 181 Group Task Description Subgroup 7004 Page 03-7004 Piston Removal, Disassembly, Inspection and Installation Preparatory operations: Cylinder head removed (01-6110). Oil pump removed (18-6023). 1 Snap rings 2 Piston pin 3 Piston Band clamp 000 589 38 31 00, arrow to engine centre. 4 Conrod bearing shells 5 Conrod with cap 6 Conrod bolts...
  • Page 182 Group Subgroup 7004 Task Description Page Special tools Removal Use a scraper to carefully remove the combustion deposits from above the top land zone in the liner. Do not damage the liner surface. Note This is to avoid damage to the piston rings when removing pistons.
  • Page 183 Group Task Description Subgroup 7004 Page Remove conrod bearing screws (6) with socket wrench. Remove bearing cap with bearing shell from conrod. Remove bearing shell from bearing cap and protect from damage. Notes When removing piston do not damage or warp oil spray nozzle.
  • Page 184 Group Subgroup 7004 Task Description Page Inspection and repair Piston Note The graphite layer on the piston skirt must not be mechanically removed or treated with strong cleaners! Caution! When using chemical substances, follow the manufacturer's instructions for use, safety instructions and waste disposal specifications.
  • Page 185 Group Task Description Subgroup 7004 Page Replace complete piston if signs of contact erosion are present at the piston edge. Remove scoring or scuffing on the top land if local and not extending as far as the first annular groove. Replace piston if damage is more extensive, i.e.
  • Page 186 Group Subgroup 7004 Task Description Page Inspecting piston pin bore Adjust bore gauge and measure pin bore. If measurements exceed the limits as per Tolerances and Wear Limits List, 03-7004, replace piston. Check bronze bush surface for wear and scoring, replace piston if necessary.
  • Page 187 Group Task Description Subgroup 7004 Page Connecting rod Note Replace conrod bolts every time the engine is disassembled. Using the magnetic crack-testing method with fluorescent penetrant powder, check conrod, conrod cap and conrod bolts for cracks. Replace cracked parts. Check condition of conrod and conrod-bolt threads for ease-of-movement. Polish out all traces of nicks in conrod, replace conrod if necessary.
  • Page 188 Group Subgroup 7004 Task Description Page Check parallelity of conrod bores. Measure permissible parallelity deviation (B) between conrod bearing and conrod bush bore to measuring distance (C). Measure distance (A) from centre conrod bearing bore to centre conrod bush bore. For required measurements and limit values, refer to the Tolerance and Wear Limits List.
  • Page 189 Group Task Description Subgroup 7004 Page Check condition of bearing shell butt and reverse side and check for friction corrosion (pitting); if there is pitting, replace shell and determine cause. Possible causes: Screws not sufficiently pretensioned, assembly fault, bearing shell spread dimension is outside tolerance limit and defective bearing support bore.
  • Page 190 Group Subgroup 7004 Task Description Page Installing conrod in piston Caution! Snap ring pretension. Risk of injury! Use correct circlip pliers. Wear protective goggles/safety mask. Using snap ring pliers (2), insert snap ring (1) into piston boss. Note Make sure snap ring is perfectly seated in groove! snap ring must sit securely in the groove.
  • Page 191 Group Task Description Subgroup 7004 Page Push associated piston pin (2) into piston and conrod (arrow) until seated against snap ring installed beforehand. Caution! Snap ring pretension. Risk of injury! Use correct circlip pliers. Wear protective goggles/safety mask. Using snap ring pliers, insert second snap ring. Note Make sure snap ring is perfectly seated in groove! Snap ring must sit securely in the groove.
  • Page 192 Group Subgroup 7004 Task Description Page Installation Installing piston with conrod Note If used pistons are reinstalled the surface of the piston rings must be visually inspected for chipping; replace piston rings as necessary (03-7312). If new pistons are to be installed, they should be assigned together with the liners according to the tolerance-group coding.
  • Page 193 Group Task Description Subgroup 7004 Page Guide band clamp over piston rings and compress to outside diameter of piston. Band clamp 000 589 38 31 00 Check code markings (arrow) on bearing cap and conrod. Insert conrod bearing shell (4) into conrod. Lug (arrow) of conrod bearing shell must be seated in groove of connecting rod.
  • Page 194 Group Subgroup 7004 Task Description Page Insert piston in cylinder liner in direction of arrow to engine centre. Press in piston until conrod bearing contacts the crankpin on crankshaft. Notes Do not damage or warp oil spray nozzle when installing piston.
  • Page 195 Group Task Description Subgroup 7004 Page Insert bearing cap and manually install conrod bearing screws. Note Markings on bearing cap and conrod must be aligned. Tighten conrod bearing screws alternately in several stages to 100 Nm and then further rotate to 90° to 100° angle of rotation.
  • Page 196 Group Subgroup 7004 Task Description Page 20080/1 E 98-12...
  • Page 197 Group Task Description Subgroup 7312 Page 03-7312 Piston Ring Removal, Inspection and Installation Preparatory operation: Piston removed (03-7004). 1 Piston ring Piston rings: See Tolerance and Wear Limits List 03-7312. Offset piston ring joints by 120°; TOP mark- ing must point upwards, pliers F3 0378 001. Special tool 20080/1 E 98-12...
  • Page 198 Group Subgroup 7312 Task Description Page Removing piston rings Set pliers to 128 mm dia. Remove rings with the pliers in sequence from top to bottom. Pliers F3 0378 001 Inspecting piston rings Replace rings during a W6 overhaul. Visually inspect surface of piston rings for chipping prior to reinstallation and after assembly;...
  • Page 199 Group Task Description Subgroup 7312 Page Installing piston rings Set pliers to 128 mm dia. Using the pliers, insert the rings in sequence from bottom to top (insert spring-loaded oil-control ring first). "TOP" marking on rings must face upwards. Offset piston ring joints by 120°. Pliers F3 0378 001 Note: The spring-loaded oil control ring has no "TOP"...
  • Page 200 Group Subgroup 7312 Task Description Page 20080/1 E 98-12...
  • Page 201 Group Task Description Subgroup 8001 Page 03-8001 Flywheel Removal and Installation Preparatory operation: Coupling removed. 1 Flywheel Guide mandrel 403 589 02 63 00. 2 Flywheel screw Re-usable until shaft length max. 75 mm, Tightening torque: 1. Stage 200 to 220 Nm, 2.
  • Page 202 Group Subgroup 8001 Task Description Page Removal/installation Remove flywheel screws (2). Installation instructions Measure shaft length (max. 75 mm) of flywheel screws. Apply a thin coat of oil when assembling. Tightening torques: 1 Stage 200 to 220 Nm. 2 Stage 90° to 100° angle of rotation Insert guide mandrels into two opposing threaded bores.
  • Page 203 Group Task Description Subgroup 8042 Page 03-8042 Flywheel Machining Preparatory operation: Flywheel removed (03-8001). Flywheel machining Clean flywheel, check for cracks and scoring. Using straightedge, check contact surface (friction surface) for evenness. Check mating face and threaded bores for crankcase support.
  • Page 204 Group Subgroup 8042 Task Description Page 20080/0 E 97-02...
  • Page 205 Group Task Description Subgroup 8312 Page 03-8312 Starter Ring Gear Replacement Preparatory operation: Flywheel removed (03-8001). 1 Ring gear Heat to between 200°C and 230°C . 2 Flywheel Starter ring gear replacement Heat ring gear and remove. Heat new ring gear to between 200°C and 230°C (yellow temper colour) and fit.
  • Page 206 Group Subgroup 8312 Task Description Page 20080/1 E 98-12...
  • Page 207 Group Task Description Subgroup 8400 Page 03-8400 Guide Bearing in Flywheel, Replacement Preparatory operation: Flywheel removed (03-8001). 1 Flywheel 2 Guide bearing Mandrel 403 589 05 15 00, Internal extractor 000 589 27 33 00, Counter support 000 589 34 33 00, Guide mandrel 403 589 02 63 00.
  • Page 208 Group Subgroup 8400 Task Description Page Replacement Remove guide bearing in flywheel. Mandrel 403 589 05 15 00 Install new guide bearing flush with screw mating face. Mandrel 403 589 05 15 00 20080/0 E 97-02...
  • Page 209 Group Task Description Subgroup 8400 Page Guide bearing replacement with installed flywheel: Remove flywheel screws. Insert guide mandrels (A) into two opposing threaded bores. Remove guide bearing with internal extractor and counter support. Install new guide bearing flush with screw mating face. A Guide mandrel 403 589 02 63 00.
  • Page 210 Group Subgroup 8400 Task Description Page 20080/0 E 97-02...
  • Page 211 Group Task Description Subgroup Page Valve Gear, Valves 20080/1 E 98-12...
  • Page 212 Group Subgroup Task Description Seite 20080/1 E 98-12...
  • Page 213 Group Task Description Subgroup Page Valve Gear, Valves Contents 05-1122 Valve clearance adjustment 05-1500 Valve stroke check 05-3133 Valve spring removal, installation and check 05-3514 Valve stem seals assembly 05-3731 Valve guide removal and installation 05-3832 Valve seat insert replacement 05-4102 Valve removal and installation 05-4202...
  • Page 214 Group Subgroup Task Description Page 20080/0 E 98-12...
  • Page 215 Group Task Description Subgroup 1122 Page 05-1122 Valve Clearance Setting Preparatory operation: Cylinder head covers removed (01-5014). Data Inlet 0.40 Valve clearance Exhaust 0.60 8V 183 Firing order 1-5-7-2-6-3-4-8 Overlap 6-3-4-8-1-5-7-2 12V 183 Firing order 1-12-5-8-3-10-6-7-2-11-4-9 Overlap 6-7-2-11-4-9-1-12-5-8-3-10 Tightening torque Locknut on adjusting screw Special tools Note...
  • Page 216 Group Subgroup 1122 Task Description Page Setting Method 1 Mount rotator with screws M8x20 on gear case. Rotator 407 589 00 63 00 Turn engine in direction of rotation until valves of a cylinder (e.g. 6th cylinder on V8 engine) overlap. The synchronous piston is now in firing TDC (e.g.
  • Page 217 Group Task Description Subgroup 1122 Page Position feeler gauge between inlet valve and rocker arm and/or between exhaust valve and rocker arm. Note Valve clearance is set correctly if it is possible to pull the gauge through with slight resistance. Gauge 0.60 mm 422 589 01 23 00 Gauge 0.40 mm...
  • Page 218 Group Subgroup 1122 Task Description Page Method 2 Data Inlet valves Inlet valves Engine 1. cylinder in: to be set to be set 8V 183 Overlap TDC 2, 5, 6, 7 3, 4, 6, 8, Firing TDC 1, 3, 4, 8, 1, 2, 5, 7, 12V 183 Overlap TDC...
  • Page 219 Group Task Description Subgroup 1122 Page Position feeler gauge between inlet valve and rocker arm and/or between exhaust valve and rocker arm. Note Valve clearance is set correctly if it is possible to pull the gauge through with slight resistance. Valve setting wrench 422 589 00 11 00 Gauge 0.60 mm...
  • Page 220 Group Subgroup 1122 Task Description Page 20080/1 E 98-12...
  • Page 221 Group Task Description Subgroup 1500 Page 05-1500 Valve Stroke Check Preparatory operations: Cylinder head cover removed (01-5014). Valve clearance set (05-1122). Valve stroke Engine 8V 183 12V 183 Valve stroke at specified Inlet 12.35 12.30 Valve clearance 11.95 11.90 Exhaust 12.30 12.25 11.90...
  • Page 222 Group Subgroup 1500 Task Description Page Position dial gauge holder. Position dial gauge with pre- load on valve head of inlet valve set scale to "0". Dial gauge 001 589 53 21 00 Dial gauge holder 363 589 02 21 00 Note Set dial gauge max.
  • Page 223 Group Task Description Subgroup 3133 Page 05-3133 Valve Spring Removal, Installation and Check Preparatory operation: Cylinder head removed (01-6110). 1 Taper element 2 Valve spring retainer 3 Valve spring, outer 4 Washer 5 Valve spring, inner 6 Valve stem seal Replace (05-3514).
  • Page 224 Group Subgroup 3133 Task Description Page Equipment Supplier Valve spring compresor Ludwig Hunger D-81309 München Spring testing scales Supplier Hahn und Kolb GmbH & Co D-70005 Stuttgart Special tool Removal Set cylinder head on support surface of valve spring compresor and secure with clamping claws. Notes All valve springs can be removed with valve spring compresor or with valve lever (A).
  • Page 225 Group Task Description Subgroup 3133 Page Checking Check valve springs with spring testing unit. If limit values are exceeded, replace valve springs. See Tolerance and Wear Limits List for limit values (05-3133). Check valve springs for indentations, flatness, burring and deformation. Flatness deviations of up to 0.2 mm on inner diameter of end coils are permissible.
  • Page 226 Group Subgroup 3133 Task Description Page 20080/1 E 98-12...
  • Page 227 Group Task Description Subgroup 3514 Page 05-3514 Valve Stem Seal Assembly Preparatory operation: Valves removed (05-4102). 6 Valve stem seals Assembly sleeve 403 589 00 61 00. 7 Washers 8 Cylinder head Special tool 20080/0 E 97-02...
  • Page 228 Group Subgroup 3514 Task Description Page Installation Lubricate valve shafts (arrows) and insert valves into valve guides. Secure cylinder head on valve spring compresor. Fit assembly sleeve (A) for valve stem seal on a valve. A Assembly sleeve 403 589 00 61 00 Press valve stem seal (6) via assembly sleeve (A) onto valve guide.
  • Page 229 Group Task Description Subgroup 3731 Page 05-3731 Valve Guide Check, Removal and Installation Preparatory operations: Injection nozzle with nozzle holder removed (07-6812). Valves removed (05-4102). Mandrel 403 589 00 15 00 1 Valve guides Reamer 000 589 12 53 00 Adjustable reamer 000 589 17 53 00 2 Cylinder head...
  • Page 230 Group Subgroup 3731 Task Description Page Check Clean valve guides with valve guide cleaning brush. Measure valve guides with plug gauge (1). If end of plug gauge (1) marked with "+" fits into valve guide, valve guide must be replaced. Replace valve guides in cylinder head if measurements, or the clearance between valve and guide, exceed or are below the limits in the Tolerance and Wear Limits...
  • Page 231 Group Task Description Subgroup 3731 Page Coat new valve guide with oil containing graphite and drive in with mandrel (A) and spacer sleeve (B). A Mandrel 403 589 00 15 00 B Spacer sleeve 403 589 00 15 00 Re-ream internal diameter of valve guide with reamer part No.
  • Page 232 Group Subgroup 3731 Task Description Page 20080/1 E 98-12...
  • Page 233 Group Task Description Subgroup 3832 Page 05-3832 Valve Seat Insert Replacement Preparatory operation: Valves removed (05-4102). Cylinder head Valve seat insert - exhaust Internal extractor 000 589 29 33 00, Counter support 000 589 34 33 00, Valve seat insert - inlet Internal extractor 000 589 30 33 00, Counter support...
  • Page 234 Group Subgroup 3832 Task Description Page Special tools Equipment Bore gauge Valve spring compressor Supplier: Ludwig Hunger 81309 München Removal Note Valve guides are installed. Fit cylinder head on valve spring compressor. Insert valves into cylinder head in accordance with markings.
  • Page 235 Group Task Description Subgroup 3832 Page Release locknut (2). Insert rotating tool (4) via pilot (5) coated in oil. Turn screw (1, rapid adjustment) until cutting tool (3) contacts pilot (5). Then push rotating tool (4) downwards until cutting tool is in centre of valve seat insert.
  • Page 236 Group Subgroup 3832 Task Description Page Note Hold knurled-head washer (10) in position and turn crank (11) clockwise to move cutting tool downwards; turn crank counterclockwise to move cutting tool upwards. Turn crank (11) clockwise and hold knurled-head washer (12) firmly. In event of increasing turning resistance, briefly release knurled-head washer (12).
  • Page 237 Group Task Description Subgroup 3832 Page Set bore gauge with micrometer. Dial gauge 001 589 53 21 00 Using bore gauge, measure basic bores for valve seat inserts in cylinder head. Check limit values according to Tolerance and Wear Limits List 05-3832 or 05-3832a. Machine to repair size as required.
  • Page 238 Group Subgroup 3832 Task Description Page Release locknut (2), fit rotating tool (4) over pilot (5) coated in oil, turn rapid adjusting screw (1) until cutting tool (15) has moved horizontally beyond the bore. Push rotating tool (4) downwards until cutting tool (15) rests on cylinder head.
  • Page 239 Group Task Description Subgroup 3832 Page Calculating setting dimension "B": Setting dimension "B" is basic bore "a" in cylinder head (see Tolerance and Wear Limits List 05-3832 or 05-3832a) and pilot diameter "A" divided by 2. Example "a" = 60 mm "A"...
  • Page 240 Group Subgroup 3832 Task Description Page Secure knurled washer (10) with mandrel (arrow) to turning crank. Turn crank (11) clockwise, simultaneously holding top knurled washer (10) for vertical advance. Recondition bore for valve seat insert until adjusting ring (18) contacts steady rest mount (16). Note Readjust cutting tool as often as necessary to achieve calculated setting dimension.
  • Page 241 Group Task Description Subgroup 3832 Page Installation Heat cylinder head to approx. 80°C in water bath. Notice! Part is hot. Risk of injury! Handle part only when wearing gloves. Insert valve seat inserts in chillbox, part No. 346 589 00 63 00, and fill with liquid nitrogen.
  • Page 242 Group Subgroup 3832 Task Description Page 20080/1 E 98-12...
  • Page 243 Group Task Description Subgroup 4102 Page 05-4102 Valve Removal and Installation Preparatory operation: Valve springs removed (05-3133). 4 Washers 6 Valve stem seals Replace (05-3514). 7 Washers 8 Cylinder head 9 Exhaust valve Lubricate valve stem. 10 Inlet valve Lubricate valve stem. Equipment Supplier Valve spring compresor...
  • Page 244 Group Subgroup 4102 Task Description Page Removal/installation Remove valve stem seals (6) from valve guides. Installation instructions Assemble valve stem seals (05-3514). Remove washers (4 and 7) for valve springs. Remove cylinder head from valve spring compresor and remove valves (9 and 10). Installation instructions Lubricate valve stems.
  • Page 245 Group Task Description Subgroup 4202 Page 05-4202 Valve Grinding Preparatory operation: Valves removed (05-4102). Valve grinding Clean removed valves and remove stubborn carbon deposits. Check valves for reusability. Surface of valve stem ends must not be damaged. Valve keyways must not be chipped and chrome layer on valve stems must be uninterrupted.
  • Page 246 Group Subgroup 4202 Task Description Page Valve stem end can be ground using the prism block mounted on the valve grinding machine. Valve length must remain above minimum permissible value. Measure valve stem with outside micrometer. For limit values, see Tolerance and Wear Limits List 05-4202 or 05-4202a.
  • Page 247 Group Task Description Subgroup 4532 Page 05-4532 Valve Seat Insert Machining Preparatory operations: Valves removed (05-4102). Note Under no circumstances should the bottom edge of the valve seat on the valve contact the inside of the cylinder head as otherwise the edge wears into the seat, the valve sealing is impaired and the valve tends to burn away. Adjust the valve seat so that the bottom edge of the valve is free.
  • Page 248 Group Subgroup 4532 Task Description Page Valve seat machining Note Valve guides are installed. Clamp cylinder head on valve spring compresor. Valve clearance measurement Insert valves. Secure dial gauge (14) to dial gauge holder (15). Mount dial gauge holder (15) on plane surface on cylinder head and feeler of dial gauge (14) on valve head with preload (approx.
  • Page 249 Group Task Description Subgroup 4532 Page Valve seat surface reconditioning Insert pilot (5) (11.9 mm dia.) into valve guide until slotted rod stop contacts valve guide; if necessary, press down slotted rod with screwdriver. Secure with mandrel inserted at top and bottom of pilot (arrows). Valve seat rotating tool 366 589 00 69 00 Secure cutting tool (3) with clamping screw to support...
  • Page 250 Group Subgroup 4532 Task Description Page Release locknut (2). Fit rotating tool (4) over pilot (5) and turn screw (1, rapid adjustment) so that cutting tool (3) is positioned on centre of valve seat. Note Carefully postition rotating tool on valve seat. Release securing screw (9) and screw knurled wheel (8) downwards.
  • Page 251 Group Task Description Subgroup 4532 Page Clamp core pin (10) in centre of guide with steady rest clamp (11) . Note The rotating tool must turn as easily as before. Raise turning device and turn rapid adjusting screw (1) to position cutting tool (3) beside inner valve seat edge. Tighten locknut (2).
  • Page 252 Group Subgroup 4532 Task Description Page Release securing screw (9) and turn knurled wheel (8) counter-clockwise approx. ½ to 2 lines of graduation (1 line of graduation = 0.1 mm). Retighten securing screw (9) and locknut of rapid adjusting screw and turn again. Hold knurled wheel in position (12) for advance and turn crank until top of cutting tool has come outwards.
  • Page 253 Group Task Description Subgroup 4532 Page Outer valve seat correction Raise turning device and release securing screw (7) of pilot rest (6). Release locknut (2). Turn rapid adjusting screw (1) so that cutting tool (3) rests on outer valve seat edge. Tighten locknut (2).
  • Page 254 Group Subgroup 4532 Task Description Page Set feeler of measuring unit with preload on valve seat centre. Check radial runout of valve seat in relation to valve guide (see Tolerance and Wear Limits List 05- 4532 or 05-4532a). Remove valve seat rotating tool, steady rest and pilots. 20080/1 E 98-12...
  • Page 255 Group Task Description Subgroup 5542 Page 05-5542 Rocker Arm Replacement Preparatory operation: Rocker shaft support removed. 1 Snap ring 2 Washer 3 Rocker arms 4 Valve adjusting screw 5 Locknut 50 Nm. 6 Screw 75 Nm. 7 Rocker shaft support 20080/1 E 98-12...
  • Page 256 Group Subgroup 5542 Task Description Page Removal/installation Clamp rocker shaft support (use protective jaws). Release locknuts (5) and remove valve setting screws (4). Installation instructions Tighten locknut (5) after adjusting valve, 50 Nm. Remove snap ring (1) for rocker arm. Remove washer (2) and rocker arm (3).
  • Page 257 Group Task Description Subgroup 6010 Page 05-6010 Valve Stroke Timing Check Data › TDC inlet 0.75 Valve stroke 0.55 With clearance-free valve adjustment TDC exhaust 0.85 0.65 Timing Inlet opens before TDC 17° At specified valve clearance Inlet closes after BDC 29°...
  • Page 258 Group Subgroup 6010 Task Description Page Special tools Check Remove cylinder head cover of first and of synchronous cylinder (01-5014). Fit rotating device (1). Rotating device 407 589 00 63 00 Set piston of 1st cylinder to TDC mark (arrow) in firing TDC.
  • Page 259 Group Task Description Subgroup 6010 Page Mount dial gauge holder on cylinder head . Position dial gauge with pre-load on valve head of inlet valve set scale to "0". Dial gauge 001 589 53 21 00 Dial gauge holder 363 589 02 21 00 Turn back engine and observe dial gauge until pointer on dial gauge is stationary.
  • Page 260 Group Subgroup 6010 Task Description Page 20080/1 E 98-12...
  • Page 261 Group Task Description Subgroup 6210 Page 05-6210 Axial Clearance of Camshaft Check Preparatory operations: Gear case cover removed (01-8000). Injection pump removed (07-8410). Special tools Checking Press camshaft on camshaft gear (arrow) in direction of gears case. Install dial gauge holder with dial gauge on crankase.Mount dial gauge with pre-load on camshaft gear and set scale to „0“.
  • Page 262 Group Subgroup 6210 Task Description Page 20080/1 E 98-12...
  • Page 263 Group Task Description Subgroup 6300 Page 05-6300 Camshaft Removal and Installation Preparatory operations: Engine removed (00-0008) Rocker shaft supports removed. Push rods removed. Engine rotated (cylinder heads facing downwards). Oil pan removed (01-7500). Gear case removed (01-8205). Removal/installation Remove tachometer drive (if installed) from crankcase at front.
  • Page 264 Group Subgroup 6300 Task Description Page 20080/1 E 98-12...
  • Page 265 Group Task Description Subgroup 7102 Page 05-7102 Camshaft Bearing Replacement Preparatory operations: Camshaft removed (05-6300). Crankshaft removed (03-4352). Oil filter housing removed (18-3031). Cooler and intercooler removed. Special tools 20080/1 E 98-12...
  • Page 266 Group Subgroup 7102 Task Description Page Removal and installation tool, Part No. 403 589 02 33 00 1 Cross handle 7 Centring pipe 2 Shell half 8 Spindle pipe 3 Bearing housing 9 Bearing retainer 4 Stop pin 10 Stop element 5 Bearing flange 11 Locating element 6 Screw M10x25...
  • Page 267 Group Task Description Subgroup 7102 Page Engine without speed transmitter Remove cap nut (27) on end cover. Remove end cover (13) from crankcase. Drift 355 589 01 63 00 Adapter 360 589 03 63 00 Remove radial-lip oil seal (29). 20080/1 E 98-12...
  • Page 268 Group Subgroup 7102 Task Description Page Insert centring pipe (7) into bearing bore and secure bearing flange (5) with two hex bolts M10x25 to crankcase. Removal and installation tool 403 589 02 33 00 Insert spindle pipe (8) into bearing flange (5). Turn spindle pipe (8) until stop pin (10) engages in groove (arrow) of spindle pipe (8).
  • Page 269 Group Task Description Subgroup 7102 Page Insert bearing retainer (9) into bearing bore and insert stop element (10) into groove behind bearing retainer (9). Turn cross handle clockwise and remove camshaft bearing. Collar bearing (21) is pressed out at rear. For this purpose, connect cross handle with bearing flange by means of shell half.
  • Page 270 Group Subgroup 7102 Task Description Page Insert spindle pipe (8) into bearing flange (5). Turn spindle pipe (8) until stop pin (10) engages in groove (arrow) of spindle pipe (8). Fit camshaft bearing (14) on bearing retainer (9), secure (arrows) and lubricate externally. Insert spindle pipe into crankcase and insert bearing retainer with camshaft bearing (14) behind relevant bearing so that camshaft bearing (14) points in direction...
  • Page 271 Group Task Description Subgroup 7102 Page Note By securing bearing retainer for spindle pipe, oil bore (15) of bearing is simultaneously aligned to oil bore (16) in crankcase. Insert stop element (10) into spindle pipe. Turn cross handle clockwise and pull in bearing until oil bore (15) of bearing is aligned with oil bore (16) in crankcase.
  • Page 272 Group Subgroup 7102 Task Description Page Install radial-lip oil seal (29). Engine with speed transmitter Install speed transmitter (B6) and tighten, 35 Nm. Fit plug-in connector (62) on speed transmitter, tighten and close seal (arrow). Engine without speed transmitter Tighten cap nut, 35 Nm. 20080/1 E 98-12...
  • Page 273 Group Task Description Subgroup Page Engine Fuel System 20080/1 E 98-12...
  • Page 274 Group Subgroup Task Description Seite 20080/1 E 98-12...
  • Page 275 Group Task Description Subgroup Page Engine Fuel System Contents 07-0001 Fuel system diagram 07-5500 Fuel lines 07-5501 Fuel fuel line removal, inspection/repair and installation 07-5580 Fuel duplex filter removal, disassembly, inspection/repair and installation 07-5580a Fuel duplex filter (with cut-out) disassembly, inspection/repair and installation 07-5700 Fuel delivery pump(s) check 07-5700/1...
  • Page 276 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 277 Group Task Description Subgroup 0001 Page 07-0001 Fuel System Diagram 8V 183 (Ship Version) 1 Engine 12 Leak-off fuel indicator* 2 Fuel delivery pump with hand pump 13 Fuel prefilter 3 Fuel duplex filter, with diverter valve 14 Drip tray 4 Fuel injection pump 15 Flexible connection 5 Fuel injection nozzle...

  • Page 278: Fuel System Diagram

    Group Subgroup 0001 Task Description Page Fuel System Diagram 12V 183 (Ship Version) 1 Engine 12 Leak-off fuel tank* 2 Fuel delivery pump 13 Leak-off fuel indicator* 3 Fuel delivery pump with hand pump 14 Fuel prefilter 4 Fuel duplex filter, with diverter valve 15 Drip tray 5 Fuel injection pump 16 Flexible connection...

  • Page 279: Fuel Lines

    Group Task Description Subgroup 5500 Page 07-5500 Fuel Lines Fuel lines to injection pump 8V 183 20080/0 E 98-04...
  • Page 280 Group Subgroup 5500 Task Description Page 1 Banjo union 26 Pipe clamp half 2 Adaptor 27 Grommet 3 Sealing ring 28 Hex bolt 4 Banjo screw 29 Washer 5 Sealing cone 30 Sealing ring 6 Nut 31 Banjo union 7 Connector 32 Fuel line from injection pump 8 Banjo screw 33 Reduction union...
  • Page 281 Group Task Description Subgroup 5500 Page Fuel lines to injection pump 12V 183 20080/0 E 98-04...
  • Page 282 Group Subgroup 5500 Task Description Page 1 Banjo union 31 Grommet 2 Adaptor 32 Hex bolt 3 Sealing ring 33 Washer Adaptor 34 Connecting lines fuel outlet from injection pump Sealing cone 6 Nut 35 Union 7 Banjo union 36 Banjo screw 8 Banjo screw 37 Banjo screw 9 Sealing ring...
  • Page 283 Group Task Description Subgroup 5500 Page Fuel line from drip tray to engine connection on free end, left side 1 Adaptor 6 Pipe clamp half 2 Sealing ring 7 Washer 3 Fuel line 8 Grommet 4 Hex bolt 9 Sealing cone 5 Hex bolt 10 Nut 20080/0 E 98-04...
  • Page 284 Group Subgroup 5500 Task Description Page Leak-off fuel lines 8V 183 T..2 (only for jacketed H.P. injection lines) 1 Leak-off fuel line from H.P. injection pressure lines 10 Spacer sleeve 2 Leak-off fuel line to distributor (leak-off fuel tank) 11 Washer 3 Banjo screw 12 Hex nut 4 Banjo screw...
  • Page 285 Group Task Description Subgroup 5500 Page Leak-off fuel lines 12V 183 T..2 (only for jacketed H.P. injection lines) 1 Leak-off fuel line 10 Sealing ring 2 Leak-off fuel line 11 Clamp 3 Leak-off fuel line to distributor (leak-off fuel tank) 12 Spacer sleeve 4 Leak-off fuel line 13 Washer...
  • Page 286 Group Subgroup 5500 Task Description Page Leak-off fuel lines 12V 183 T..3 (only for jacketed H.P. injection lines) 1 Leak-off fuel line 11 Washer 2 Leak-off fuel line 12 Hex nut 3 Leak-off fuel line 13 Hex bolt 4 Banjo screw 14 Sealing ring 5 Banjo screw 15 Plug...
  • Page 287 Group Task Description Subgroup 5501 Page 07-5501 Fuel Line Removal, Inspection/Repair and Installation Removal Before removing the fuel lines, it is advisable to photograph the engine from all sides or affix metal tags to the lines so that they can be reinstalled in their original positions. Notice! Fuels and fuel vapours are inflammable and toxic.
  • Page 288 Group Subgroup 5501 Task Description Page Check union nut threads and threaded connections for obstructions: recondition or replace part if necessary. Tighten connections and adapters. Check condition of hoses and for signs of ageing; replace if necessary. Inspect brackets, grommets and mounting components of fuel lines for damage and wear; replace if necessary. Check condition of threads of union nut and adapter.

  • Page 289: Fuel Duplex Filter Removal, Disassembly, Inspection/Repair And Installation

    Group Task Description Subgroup 5580 Page 07-5580 Fuel Duplex Filter Removal, Disassembly, Inspection/Repair and Installation Fuel duplex filter 1 Fuel duplex filter 12 Bracket 2 Filter head 13 Thread insert 3 Filter element 14 Screw 4 Sealing ring 15 Screw 5 Housing 16 Bracket 6 Screw...
  • Page 290 Group Subgroup 5580 Task Description Page Fuel duplex filter Filter head Connection, pressure relief valve Securing screw Vent plug Filter housing Felt-filter element 20080/1 E 98-12...
  • Page 291 Group Task Description Subgroup 5580 Page Preparatory operations: Drain fuel from duplex filters Remove fuel lines (07-5500 and 07-5501). Removal Remove nuts and securing screws, Remove fuel duplex filter from carrier. Remove carrier from engine. Remove overflow valves. Remove filter elements (see Operating Instructions). Inspection and repair Clean all components.
  • Page 292 Group Subgroup 5580 Task Description Page 20080/1 E 98-12...
  • Page 293 Group Task Description Subgroup 5580a Page 07-5580a Fuel Duplex Filter Removal, Disassembly, Inspection/Repair and Installation Fuel duplex filter (with cut-out) 1 Fuel duplex filter 6 Sealing ring 2 Hex bolt 7 Clamp 3 Washer 8 Clamp 4 Vent valve 9 Hex bolt 5 Tube 10 Washer 20080/1 E 98-12...
  • Page 294 Group Subgroup 5580a Task Description Page Fuel duplex filter 1 Spring 8 Sealing ring 2 Threaded pin 9 Filter element with gasket 3 Sealing ring 10 Cover 4 Sealing ring 11 Sealing ring 5 Plug 12 Filter head 6 3-way cock 13 Vent plug (not provided if 7 Plug vent valves installed)
  • Page 295 Group Task Description Subgroup 5580a Page Preparatory operations: Drain fuel from duplex filters Remove fuel lines (07-5500 and 07-5501). Removal Remove tubes on vent valves. Remove vent valves. Remove filter elements (see Operating Instructions). Remove filter head from carrier. Inspection and repair Clean all components.
  • Page 296 Group Subgroup 5580a Task Description Page 20080/1 E 98-12...

  • Page 297: Fuel Delivery Pump(S) Check

    Group Task Description Subgroup 5700 Page 07-5700 Fuel Delivery Pump(s) Check A Measuring delivery pump vacuum Connect testing equipment (1), part No. 617 589 04 21 00, between supply line from fuel tank and fuel prefilter. Start engine. When hose (arrow) is compressed, pressure gauge displays vacuum in delivery pump(s), 0.5 to 0.8 bar.
  • Page 298 Group Subgroup 5700 Task Description Page B Pressure of delivery pump(s) and opening pressure of overflow valve measurement Connect testing equipment (1), part No. 617 589 04 21 00 between delivery pump and fuel filter. Start engine. Pressure gauge displays opening pressure of overflow valve (2), min. 1.3 bar. When hose (arrow) is compressed, pressure gauge displays pressure of delivery pump, >2.0 bar.

  • Page 299: C Measuring Fuel Filter Flow Rate

    Group Task Description Subgroup 5700 Page C Measuring fuel filter flow rate Connect testing equipment (1) part No. 617 589 04 21 00 between fuel filter outlet and injection pump. Start engine. Pressure gauge displays filter output pressure, min. 1.3 bar. Note During measurements it can be seen whether diesel fuel flowing through pipework is bubble-free.
  • Page 300 Group Subgroup 5700 Task Description Page 20080/0 E 97-02...
  • Page 301 Group Task Description Subgroup 6712 Page 07-6712 Fuel Injector Check Preparatory operation: Fuel injector removed (07-6812). Injection pressure 1) Setting value 200 +8 bar Lowest permissible value for worn nozzles 1) Difference in nozzle pressure within engine must not exceed 10 bar. Special tool Fuel Injector Check Notice!
  • Page 302 Group Subgroup 6712 Task Description Page Note: Combustion deposits around the nozzle openings strongly influence the spray pattern. Connect test line (6) to injector (5). Fill test-oil container (7) with ISO 4113 test oil. Carry out pre-check, opening-pressure check, leak test and visual inspection of nozzle openings.
  • Page 303 Group Task Description Subgroup 6712 Page Opening Pressure Check Open shut-off valve (2) on pressure gauge (1). Slowly push pump lever (4) downwards. Note!If the pressure gauge is connected, allow the pressure to increase and decrease slowly to avoid damage to the gauge. Read off the opening pressure on the gauge at opening of the nozzle or begin of injection spray.
  • Page 304 Group Subgroup 6712 Task Description Page Visual inspection of possibly obstructed nozzle openings. Switch off pressure gauge of test device. Push pump lever down as fast as possible, at least twice per second. A Spray Pattern Check Spray jets must correspond to number of openings. B Visual Inspection of Nozzle Openings.

  • Page 305: Injector Disassembly, Cleaning And Assembly

    Group Task Description Subgroup 6750 Page 07-6750 Injector Disassembly, Cleaning and Assembly Preparatory operation: Fuel injector removed (07-6812). 1 Thrust nut 80 Nm, Socket 403 589 00 13 00 2 Nozzle Ultrasonic cleaning unit 3 Intermediate washer with locating pin 4 Thrust pin 5 Compression spring 6 Washer...
  • Page 306 Group Subgroup 6750 Task Description Page Recommended equipment and cleaning fluids Magnifying glass with lamp (min. 6 x enlargement) Commercially available tool Order No. (Manufacturer) Ultrasonic cleaning equipment Equipment model: SONOREX SUPER RK 100 SH Nozzle holder: ED 8 Basket: K 3 S Cover: D 3B...
  • Page 307 Group Task Description Subgroup 6750 Page Fuel Injector Disassembly Ensure greatest workplace cleanliness during disassembly and assembly of injectors! If more than one injector are disassembled, ensure that the individual components of each injector remain together and are not interchanged with components from other injectors.
  • Page 308 Group Subgroup 6750 Task Description Page Cleaning complete nozzle holder combinations: Position nozzle holder combinations vertically into the bracket ED 8 and clean in the ultrasonic bath. The duration of the cleaning process depends on the level of contamination but must be at least 10 minutes. Cleaning nozzle elements: When cleaning the nozzle elements, remove the nozzle needle completely from the body and clean two parts...
  • Page 309 Group Task Description Subgroup 6750 Page After cleaning, visually inspect used nozzles to confirm cleaning process has been successful. With nozzle holder assemblies and nozzle elements: − Examine orifice outlet edge for mechanical damage. With nozzle elements: − If damage or coarse areas are found on the needle seat of the nozzle needle, replace nozzle completely. −...
  • Page 310 Group Subgroup 6750 Task Description Page Fuel Injector Assembly Clean injectors as described before re-assembling. Check compression spring (6) for cracks and the thrust pin for wear, replace if necessary. Position nozzle holder (8) vertically in support. Insert washer (7), compression spring and thrust pin into holder.

  • Page 311: Injector Removal And Installation

    Group Task Description Subgroup 6812 Page 07-6812 Injector Removal and Installation 25 Nm, Box wrench (open) 000 589 07 03 00, 1 Injection line Serrated wrench 000 589 50 03 00, Box wrench insert 000 589 68 03 00. 2 Thrust screw 70 Nm, Pin wrench 403 589 03 07 00,...
  • Page 312 Group Subgroup 6812 Task Description Page Special tools Fuel Injector Removal Notice! No naked flames and no smoking when working on the fuel system! Do not spill fuel! Remove union nut of injection line on nozzle holder. Box wrench (open) 000 589 07 03 00 20080/1 E 98-12...
  • Page 313 Group Task Description Subgroup 6812 Page Remove union nut of injection line on injection pump; hold pipe connection in position with serrated wrench. Remove all pipe clamps from injection line and remove line. Note Do not bend injection line. Box wrench (open) 000 589 07 03 00 Serrated wrench 000 589 50 03 00,...
  • Page 314 Group Subgroup 6812 Task Description Page Install impact puller on injector (3), remove injector. Remove sealing ring from cylinder head. Removal tool 355 589 01 63 00 Clean nozzle externally, also remove combustion deposits from nozzle body end (mainly at the nozzle openings) with a wooden scraper and fuel.
  • Page 315 Group Task Description Subgroup 6812 Page Lightly hand-tighten the injection line on the injection pump and injector. Install pipe clamps. Tighten union nut of injection line on injection pump with box-wrench socket and torque wrench. Tightening torque: 25 Nm. Lubricant: Engine oil Tighten union nut of injection line on injector with box- wrench and torque wrench.
  • Page 316 Group Subgroup 6812 Task Description Page 20080/1 E 98-12...

  • Page 317: Start Of Delivery Check

    Group Task Description Subgroup 8234 Page 07-8234 Start of Delivery Check Note: Carry out start of delivery check only if performance is reduced or specific fuel consumption high. 1 High pressure pump Part No. 422 589 00 71 00 7 Injection pump lever Set to full load and lock 2 Fuel tank 8 Injection pump...
  • Page 318 Group Subgroup 8234 Task Description Page Tightening torques Injection lines Bracket for fuel filter on gear case cover Drive gear to injection pump Special tools For injection pump start of delivery, see Engine Acceptance Test Record ! Check Notice! Risk of fire and explosion! When working on fuel system, catch fuel emerging.
  • Page 319 Group Task Description Subgroup 8234 Page Engines with electronic diesel control: Remove supply line (15) to injection pump and connect to test line (12). Special wrench 000 589 50 03 00 Test line 442 589 01 90 00 Connect H.P. pump, supply line part No.
  • Page 320 Group Subgroup 8234 Task Description Page Engines without electronic diesel control: Remove fuel supply line to injection pump. Connect H.P. pump, supply line (8) part No. 422 589 00 71 00. Remove return line and overflow valve on injection pump. Seal injection pump return with plug (5) from adapters, part No.
  • Page 321 Group Task Description Subgroup 8234 Page Bar engine slowly in direction of rotation and observe fuel flow in sight glass until spray pattern shows correct atomisation. The exact pump timing is achieved at the transition. A = Good atomisation B = Poor atomisation "just before start of delivery" C = Faulty atomisation (droplets) Note For engines with split-element injection pump:...
  • Page 322 Group Subgroup 8234 Task Description Page A = Good atomisation B = Fuel dribble "just before start of delivery" (pre-injection) C = Droplets, start of delivery, pre-injection D = Again good atomisation E = Fuel dribble "just before start of delivery" (main injection) F = Droplets, start of delivery, main injection Remove plug from gear case cover.
  • Page 323 Group Task Description Subgroup 8234 Page If it is necessary to correct the start-of-delivery position, set engine - in direction of rotation - exactly to start of delivery between flywheel and inspection port edge (arrow). Remove gear case cover (01-8000) and release hex bolts (16) on drive gear.
  • Page 324 Group Subgroup 8234 Task Description Page Tighten hex bolts (16) on drive gear, 35 Nm. Repeat start of delivery test. Install gear case cover and seal (01-8000). Remove H.P. pump, part No. 422 589 00 71 00. Tighten injection line, 25 Nm. Tighten fuel supply line, 25 Nm.

  • Page 325: Installing And Removing Injection Pump

    Group Task Description Subgroup 8410 Page 07-8410 Installing and Removing Injection Pump Preparatory operations: Charge-air manifold removed (09.8621). 1 Injection pump Assembly gauge 422 589 63 00 2 Drive gear 3 Hex bolt 35 Nm 4 Washer 5 Double-hex screw For tightening diagram, see Page 8 6 Double-hex screw For tightening diagram, see Page 8...
  • Page 326 Group Subgroup 8410 Task Description Seite Danger! Risk of fire and explosion! Catch any fuel emerging when working on the fuel system. After working on fuel system, start engine. Check fuel system for leaks. Special tools Injection line arrangement 8 V 183 12 V 183 20080/1 E 98-12...
  • Page 327 Group Task Description Subgroup 8410 Page Removal Remove charge air manifold from intercooler (only with top-mounted intercooler). Disconnect fuel lines from injection pump. Serrated wrench 000 589 50 03 00, Remove union nut of injection lines from nozzle holder and from injection pump. Hold pipe connection at injection pump firmly in position.
  • Page 328 Group Subgroup 8410 Task Description Seite Remove oil pressure line to turbocharger. Remove oil separator (01-9751). Disconnect fuel lines from injection pump. Release ball socket (11) on control lever of injection pump and press off from ball head. Note As engine versions differ, the illustration shows one example.
  • Page 329 Group Task Description Subgroup 8410 Page Remove gear case cover (13) from above. Remove double-hex screws (2) from injection pump and remove injection pump (example). Remove hex screws (7). Remove drive gear (5) from drive flange. 20080/1 E 98-12...
  • Page 330 Group Subgroup 8410 Task Description Seite Remove sealing ring (4) from injection pump. Installation Install rotator with M8x20 screws on gear case and turn engine in compression stroke of first cylinder until mark for start of delivery is aligned with edge (arrow) in inspection port.
  • Page 331 Group Task Description Subgroup 8410 Page Install drive gear (5) on drive flange. Note Do not fully tighten hex screws (7). Turn injection pump camshaft until mark on drive flange is aligned with mark on injection pump (arrow). Move injection pump drive gear to central position in elongated holes.
  • Page 332 Group Subgroup 8410 Task Description Seite Fit assembly gauge on injection pump and secure with knurled-head screw (arrow). Move injection pump to and fro until assembly gauge is in contact with crankcase. Assembly gauge 422 589 01 63 00 Tighten injection pump screws with washers in specified sequence in the following stages: Double-hex screws for 8/12V 183 to 1000 PS...
  • Page 333 Group Task Description Subgroup 8410 Page Tighten hex bolts (7) on drive gear, 35 Nm. Install gear case cover and seal. (01-8000). Install fuel lines with new gaskets and tighten, 30 Nm. Coat pushrod seat (11) of engine control with long duration grease, press on control lever of injection pump and secure.(Example).
  • Page 334 Group Subgroup 8410 Task Description Seite Tighten oil pressure line with new gasket on turbocharger and new sealing rings on crankcase, 25 Fit injection lines free of tension and tighten, 25 Nm. Hold pipe connection of injection pump firmly in position.

  • Page 335: Injection Lines

    Group Task Description Subgroup 9200 Page 07-9200 Injection Lines Injection lines, 8V 183 1 Set of injection lines Cylinders 1 to 4 2 Set of injection lines Cylinders 5 to 8 3 Spacer 4 Hex bolt 5 Hex bolt 20080/0 E 97-02...
  • Page 336 Group Subgroup 9200 Task Description Page Injection lines, 12V 183 1 Set of injection lines Cylinders 1 to 6 2 Set of injection lines Cylinders 7 to 12 3 Spacer 4 Hex bolt 5 Hex bolt 20080/0 E 97-02...

  • Page 337: Injection Line Removal, Inspection/Repair And Installation

    Group Task Description Subgroup 9224 Page 07-9224 Injection Line Removal, Inspection/Repair and Installation Removing pressure lines Disconnect H.P. fuel lines from cylinder heads. Disconnect H.P. fuel lines from injection pump. Remove hex bolts from charge air lines. Remove H.P. fuel lines and spacers. Inspection and repair Clean all components.
  • Page 338 Group Subgroup 9224 Task Description Page Important Information: A Damage to injection lines Damage is often detected on the engine's injection lines: • Lines leaking at sealing cones • Scuffed lines • Ruptured lines Damage can be avoided if attention is paid to the following points: 1.
  • Page 339 Group Task Description Subgroup 9224 Page B Measures to prevent foreign bodies entering injection lines and injection nozzles during repair work Foreign bodies may enter the area of the nozzle injection bores and result in the following complaints: • Engine shaking, uneven operation •...
  • Page 340 Group Subgroup 9224 Task Description Page 20080/1 E 98-12...
  • Page 341 Group Task Description Subgroup Page Air Filter, Exhaust Turbocharger, Charge Air Lines 20080/1 E 98-12...
  • Page 342 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 343 Group Task Description Subgroup Page AIR FILTER, EXHAUST TURBOCHARGER, CHARGE AIR LINES Contents 09-1030 Air filter removal and replacement 09-6010 Exhaust turbocharger check, examination, fault diagnosis 09-6030 Exhaust turbocharger removal and installation (Engine version with top-mounted turbocharger) 09-6030a Exhaust turbocharger removal and installation (8V/12V 183 T..3) 09-6263 Exhaust turbocharger disassembly and assembly 09-6800...
  • Page 344 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 345 Group Task Description Subgroup 1030 Page 09-1030 AIR FILTER REMOVAL AND REPLACEMENT Removal Release clamp (3) and remove air filter (2). Replace damaged filter. Always replace air filters during W5 and W6 maintenance. Remove contamination indicator (1). Installation Screw contamination indicator (1) into new filter - reference dimension approx.
  • Page 346 Group Subgroup 1030 Task Description Page 20080/0 E 97-02...
  • Page 347 Group Task Description Subgroup 6010 Page 09-6010 Exhaust Turbocharger Check, Examination, Fault Diagnosis Data K27/29 Turbocharger Permissible axial clearance up to max. 0.16 mm 0.16 mm 0.16 mm 0.16 mm Permissible radial clearance up to max. 0.45 mm 0.46 mm 0.58 mm 0.57 mm Special tools...
  • Page 348 Group Subgroup 6010 Task Description Page Axial clearance check Remove turbocharger (09-6030). Clamp turbocharger in vice. Note Use protective jaws. Fit dial gauge on turbine wheel hub. Press rotor shaft down and set dial gauge to "0". Press rotor shaft against dial gauge and read off clearance.
  • Page 349 Group Task Description Subgroup 6010 Page Fault diagnosis Malfunction Cause Remedy Exhaust opacity and power reduction Air filter heavily contaminated. Clean or replace air filter element. Replace Donaldson air filter. Turbine or compressor wheel Repair or replace turbocharger. scrapes against housing. Foreign bodies in exhaust.
  • Page 350 Group Subgroup 6010 Task Description Page Malfunction Cause Remedy Whistling noises in area of Leaks at: Replace faulty gaskets. turbocharger - Flange connections or gaskets on Check tightness and security of air and exhaust pipework. flanges and connections. - Flange seals (shape) Check whether gaskets jut into pipe cross-sections.

  • Page 351: 09-6030 Exhaust Turbocharger Removal And Installation

    Group Task Description Subgroup 6030 Page 09-6030 EXHAUST TURBOCHARGER REMOVAL AND INSTALLATION Engine 8V 183 T..2 (Engine version with top-mounted intercooler and turbocharger K27) 1 Exhaust turbocharger, left 2 Exhaust turbocharger, right 3 O-Ring replace 4 Hex nut replace Lubricant: Assembly paste Tightening torque: 50 Nm.
  • Page 352 Group Subgroup 6030 Task Description Page Engine 8V 183 T..2 (Engine version with compact intercooler and turbocharger K27) 1 Exhaust turbocharger, left 2 Exhaust turbocharger, right 3 O-Ring replace 4 Stud 5 Hex nut replace 6 Spring washer 20080/1 E 98-12...
  • Page 353 Group Task Description Subgroup 6030 Page Engine 12V 183 T..2 (Engine version with exhaust turbocharger K36) 1 Exhaust turbocharger, left 2 Exhaust turbocharger, right 3 Gasket replace 4 Stud 5 Hex nut replace 6 Spring washer 20080/1 E 98-12...
  • Page 354 Group Subgroup 6030 Task Description Page Preparatory operations: Air filter removed (09-1030). Oil supply and return lines removed (18-1600). Connecting line to intercooler removed. Vent lines removed. Note: The removal and installation instructions apply to both turbochargers. Before the turbocharger is removed, the intake line before the compressor, the exhaust elbows and exhaust lines, as well as the oil supply and return lines, must be checked for foreign bodies, contamination and damage.

  • Page 355: 09-6030A Exhaust Turbocharger Removal And Installation (8V/12V 183 T

    Group Task Description Subgroup 6030a Page 09-6030a Exhaust Turbocharger removal and installation Engine 8V/12V 183 T..3 (with exhaust turbocharger K29 or K37) Exhaust turbocharger, left 1 Carrier housing 17 Cover 2 Carrier housing upper section 18 Hex screw 3 Carrier housing lower section 19 Washer 4 Washer 20 Cover...
  • Page 356 Group Subgroup 6030a Task Description Page Exhaust turbocharger, right 1 Carrier housing 11 Washer 2 Carrier housing upper section 12 Tab washer 3 Carrier housing lower section 13 Tab washer 4 O-ring 14 O-ring 5 Stud 15 Cover 6 Stud 16 Sealing ring 7 Hex screw 17 Plug...
  • Page 357 Group Task Description Subgroup 6030a Page Preparatory operations: Air filter removed (09-1030). Oil supply and return lines removed (18-1600). Connecting line to intercooler removed. Vent lines removed. Air line to vent valve (waste gate) removed. Note The removal and installation instructions apply to both turbochargers. Before the turbocharger is removed, the intake line before the compressor, the exhaust elbows and exhaust lines, as well as the oil supply and return lines, must be checked for foreign bodies, contamination and damage.
  • Page 358 Group Subgroup 6030a Task Description Page Installation Note: Carry out installation operations in accordance with arrangement drawings 506 002 27 14 and 506 002 28 14. Exhaust line and carrier housing lower section are installed. Fit plug-in pipes (8) in exhaust line (7). Installation instructions: Plug-in pipe with bores in long duct (direction of exhaust outlet).
  • Page 359 Group Task Description Subgroup 6030a Page Coat carrier housing upper section with sealing paste (aux. material No. 50545) at mating surface to lower section and turbocharger. Thread upper section onto turbocharger, maintaining distance to turbocharger flange-mounting surface. After installing turbocharger securing screws and tab washers, position upper section on turbocharger flange-mounting surface.
  • Page 360 Group Subgroup 6030a Task Description Page 20080/1 E 98-12...

  • Page 361: Exhaust Turbocharger Disassembly And Assembly

    Group Task Description Subgroup 6263 Page 09-6263 EXHAUST TURBOCHARGER DISASSEMBLY AND ASSEMBLY SEE SPECIAL PUBLICATION. 20080/0 E 98-04...
  • Page 362 Group Subgroup 6263 Task Description Page 20080/0 E 98-04...

  • Page 363: Intercooler Leak Check

    Group Task Description Subgroup 6800 Page 09-6800 INTERCOOLER LEAK CHECK 20080/0 E 97-02...
  • Page 364 Group Subgroup 6800 Task Description Page 20080/0 E 97-02...

  • Page 365: Intercooler Removal And Installation (Engine Version With Top-Mounted Intercooler)

    Group Task Description Subgroup 6810 Page 09-6810 Intercooler Removal and Installation (Engine version with top-mounted intercooler) 1 Intercooler, installed with sealing paste, aux. material No. 11 Hex screw 50546 2 Socket-head screw 12 Washer 3 Washer 13 Bracket 4 Intercooler 14 Bracket 5 Sealing ring, replace 15 Bracket...
  • Page 366 Group Subgroup 6810 Task Description Page 20080/1 E 98-12...

  • Page 367: (Engine Version With Compact Intercooler)

    Group Task Description Subgroup 6810a Page 09-6810A Intercooler Removal and installation (Engine version with compact intercooler) 1 Connecting housing, sealing paste, part No. 50546 13 Socket-head screw 2 Plug 14 Socket-head screw 3 Sealing ring, replace 15 Washer 4 Intercooler 16 Hex screw 5 Hex screw 17 Washer...
  • Page 368 Group Subgroup 6810a Task Description Page 20080/1 E 98-12...

  • Page 369: Charge Air Lines Removal And Installation

    Group Task Description Subgroup 6812 Page 09-6812 Charge Air Lines Removal and Installation (Engine version with top-mounted intercooler) Crankcase breather and intake elbow 1 Hex screw 12 Cylinder head cover 2 Washer 13 Oil separator 3 Intake elbow before turbocharger 14 Intake hose 4 Bracket 15 Clamp...
  • Page 370 Group Subgroup 6812 Task Description Page Charge air manifold and charge air lines 1 Charge air manifold 14 Charge air manifold, left (charge air line) 2 Sealing ring, replace 15 Charge air manifold, right (charge air line) 3 Plug 16 Plug 4 Gasket, replace 17 Sealing ring, replace 5 Flange...

  • Page 371: 09-6812A

    Group Task Description Subgroup 6812a Page 09-6812A Charge Air Lines Removal and Installation (Engine version with compact intercooler) Crankcase breather and intake elbow 1 Cylinder head cover 13 Clamp 2 Oil separator 14 O-ring, replace 3 Intake hose 15 Plug-in pipe 4 Clamp 16 O-ring, replace 5 Intake elbow...
  • Page 372 Group Subgroup 6812a Task Description Page Air supply housing and charge air lines 1 Air supply housing *, sealing paste, aux. material No. 50546 13 Charge air line, left 2 Hex screw 14 Plug 3 Hex screw 15 Sealing ring, replace 4 Washer 16 Hex screw 6 Plug-in pipe with bell...

  • Page 373: Emergency Air Shut-Off Flap Removal And Installation

    Group Task Description Subgroup 6820 Page 09-6820 Emergency Air Shut-Off Flap Removal and Installation (Engine version with top-mounted intercooler) 1 Bearing bush 11 Lever, right side 2 Shaft seal 12 Lever, left side 3 O-ring, replace 13 Spring pin 4 Shaft 14 Hex screw 5 Flap 15 Washer...
  • Page 374 Group Subgroup 6820 Task Description Page Shutdown system for emergency air shut-off flap 1 Bracket 15 Spring washer 2 DC solenoid 16 Hex screw 3 Flange 17 Cable entry 4 Spring washer 18 Threaded bush 5 Hex screw 19 Insert 6 Spring washer 20 Washer 7 Hex screw...
  • Page 375 Group Task Description Subgroup 6820 Page Arrangement of emergency air shut-off flap with shutdown system Bracket 15 Flap Lever, right side 16 Key Miltac microswitch 17 Lockwasher Pull rod 18 DC solenoid Lever, left side 19 Flange Bracket 20 O-ring Spring pin 21 Lever Shaft...
  • Page 376 Group Subgroup 6820 Task Description Page 20080/1 E 98-12...

  • Page 377: 09-6820A

    Group Task Description Subgroup 6820a Page 09-6820a Emergency Air Shut-Off Flap Removal and Installation (Engine version with compact intercooler) 1 Miltac microswitch 16 Key 28 Dowel pin 2 Cable entry 17 Grease nipple 29 Lever 3 Threaded bush 18 Bearing bush, 30 Cam 4 Insert Surface sealant...
  • Page 378 Group Subgroup 6820a Task Description Page Arrangement of emergency air shut-off flap with shutdown system 1 Flange 8 Bending spring 2 DC solenoid 9 Lever 3 Bracket 10 Axle 4 Lever 11 Grease nipple 5 Bearing bush 12 Control cam 6 Flap 13 Grease nipple 7 Shaft...
  • Page 379 Group Task Description Subgroup Page Belt Drives, Air Compressor 20080/1 E 98-12...
  • Page 380 Group Subgroup Task Description Seite 20080/1 E 98-12...
  • Page 381 Group Task Description Subgroup Page Belt Drives, Air Compressor Contents 13-1001 Belt drive: Installation of V-belts, adjustment specifications, tension check, installation of clamps (Example: ship version with alternator and raw water pump) 13-1001a Belt drive: Installation of V-belts, adjustment specifications, tension check, installation of clamps (Example: ship version without alternator with tension roller) 13-1402...
  • Page 382 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 383 Group Task Description Subgroup 1001 Page 13-1001 Belt Drive: Installation Of V-Belts, Adjustment Specifications, Tension Check, Installation of Clamps (Example: ship version with alternator and raw water pump) 1 and 3 Screw for clamping element 13 M 12x50 screw for ball joint 2 and 4 Clamping nut with bush 5 and 6 Clamping screw...
  • Page 384 Group Subgroup 1001 Task Description Page View Z 20080/1 E 98-12...
  • Page 385 Group Task Description Subgroup 1001 Page V-belt installation 1. Grooves must be clean and free from oil. 2. Check belt pulleys for axial alignment in at least two positions, offset by 180° to each other. Deviation of pulley alignment, max. permissible: Between pulley on crankshaft and pulley on alternator ±...
  • Page 386 Group Subgroup 1001 Task Description Page Fitting stress bolts: (Lubricant: engine oil for all threaded unions) 1. Before tensioning the V-belt for the raw water pump, release screws 7 (see Page 2, View Z) and screw No. 8 (do not remove). 2.
  • Page 387 Group Task Description Subgroup 1001a Page 13-1001a belt Drive: Installation of v-Belts, Adjustment Specifications, tension Check, Installation of Clamp (Example: ship version without alternator with tension roller) 1 Screw for clamping element 2 Clamping nut 3 Clamping screw 20080/1 E 98-12...
  • Page 388 Group Subgroup 1001a Task Description Page Bracket 23 Ball joint, fitted with thread-locking agent, Tension roller, filled with antifriction bearing grease, aux. material No. 40083 aux. material No. 50524 24 Hex screw 25 Washer Ball bearing 26 Washer Securing element 27 Hex nut Sealing ring 28 V-belts...
  • Page 389 Group Task Description Subgroup 1001a Page V-belt installation 1. Grooves must be clean and free from oil. 2. Check belt pulleys for axial alignment in at least two positions, offset by 180° to each other. Deviation of pulley alignment, max. permissible: Between pulley on crankshaft and pulley on tensioning roller ±...
  • Page 390 Group Subgroup 1001a Task Description Page Fitting stress bolts: (Lubricant: engine oil for all threaded unions) 1. Secure ball joint to tightening torque (74 + 7 Nm) and lock threaded rod in ball joint. 2. Screws 1 must only be fitted first by hand only. 3.
  • Page 391 Group Task Description Subgroup 1402 Page 13-1402 V-Belt Replacement (Example: ship version) Data V-belt tension 500 to 600 N worn 350 to 450 N Special tool Replacement Release clamping screw (1) on alternator and/or raw water pump and/or tension roller. Release V-belt with clamping nut (2) and remove via belt pulley.
  • Page 392 Group Subgroup 1402 Task Description Page 20080/1 E 98-12...
  • Page 393 Group Task Description Subgroup 7001 Page 13-7001 Compressor Disassembly and Assembly Preparatory operation: Gear case cover removed (01-8000). A Compressor with piston diameter 90 mm 20080/1 E 98-12...
  • Page 394 Group Subgroup 7001 Task Description Page 1 Hex screw, intermediate plate 30 Nm. 2 Hex screw, cylinder head 30 Nm. 3 Cylinder head 4 Gasket replace. 5 Hex screw 15 Nm. 6 Spacer bushing 7 Bracket 8 Washer 9 Delivery valve diaphragm 10 Intermediate plate 11 Suction valve diaphragm 12 Gasket...
  • Page 395 Group Task Description Subgroup 7001 Page B Compressor with piston diameter 100 mm 20080/1 E 98-12...
  • Page 396 Group Subgroup 7001 Task Description Page 46 Hex screw, cylinder head 30 Nm. 47 Hex screw, intermediate plate 30 Nm. 48 Cylinder head 49 Gasket replace. 50 Hex nut 15 Nm. 51 Valve plates 52 Delivery valve diaphragm 53 Intermediate plate 54 Suction valve diaphragm 55 Gasket replace...
  • Page 397 Group Task Description Subgroup 7001 Page Piston clearance/projection (to upper edge of cylinder liner) 1 cylinder dia. 90 mm - 0.16 to - 1.09 2 cylinders dia. 90 mm - 1.66 to - 2.59 1 cylinder dia. 100 mm + 0.09 to -0.71 Tightening torques Steering assist pump on gear case Bearing cap on gear case...
  • Page 398 Group Subgroup 7001 Task Description Page Special tools A Compressor with piston diameter 90 mm Note When installing a new compressor or replacement engine, check the compressor H.P. line for carbonisation. If the line is restricted, the H.P. lines and pressure regulator must be replaced.
  • Page 399 Group Task Description Subgroup 7001 Page Remove cylinder head (3) with intermediate plate. Unscrew cylinder liner (arrows) and remove over piston. Remove snap ring (19) for piston pin (20). Press out piston pin (20) and remove piston. 20080/1 E 98-12...
  • Page 400 Group Subgroup 7001 Task Description Page Remove side cover (39). Remove conrod (24) together with bearing cap and bearing shells. Remove steering assist pump (37) and driver disc (38). 20080/1 E 98-12...
  • Page 401 Group Task Description Subgroup 7001 Page Place locking device over crankshaft and secure. Note The crankshaft must be rotated until the crankpin is facing upwards. Locking device 442 589 09 63 00 Unscrew hex screw on front drive gear (32) with box wrench insert and remove drive gear (32) with hex screw.
  • Page 402 Group Subgroup 7001 Task Description Page Remove lockwasher (29) for bearing. Withdraw bearing (31) with internal extractor and customer-furnished support plate. Internal extractor 000 589 28 33 00 Spindle from counter-support 000 589 34 33 00 Use mandrel to remove bearing bush from bearing flange.
  • Page 403 Group Task Description Subgroup 7001 Page Remove hex screw (1) from cylinder head. Remove cylinder head gasket (12) and suction valve diaphragm (11). Remove intermediate plate (10) and gasket (4). 20080/1 E 98-12...
  • Page 404 Group Subgroup 7001 Task Description Page Remove delivery valve diaphragm (9) from intermediate plate. Assembly Install bearing bush (26) in the bearing flange (25) and recondition with a reamer. See Tolerances and Wear Limits List for specified values (13-7001). Note The oil bores in the bearing bush (26) and bearing flange (25) must be aligned.
  • Page 405 Group Task Description Subgroup 7001 Page Position roller bearing so that collar of bearing inner race points towards fan. Install roller bearing in bearing cap. Mandrel 198 589 03 39 00 Remove metal washers. Install bearing cap (29) and tighten hex screws (50 Nm).
  • Page 406 Group Subgroup 7001 Task Description Page Hold roller bearing inner race firmly in position and install crankshaft (28). Replace O-ring (27). Oil bearing flange (25) at fit and O-ring (27), place on housing and crankshaft. Oil bores (arrows) in housing and in bearing flange (25) must be aligned.
  • Page 407 Group Task Description Subgroup 7001 Page Mount drive gear (32) with hex screw. Place locking device over crankshaft and secure. Locking device 422 589 09 63 00 20080/1 E 98-12...
  • Page 408 Group Subgroup 7001 Task Description Page Tighten hex screw of drive gear (270 Nm). Note This value corresponds to an actual torque of 360 Nm. Torque wrench (40), ratchet adapter (41) and box wrench (42) must be positioned in one line with respect to each other.
  • Page 409 Group Task Description Subgroup 7001 Page Install conrod (24) with conrod cap and bearing shells, tighten conrod bolts to 30 Nm. Place piston over conrod and install piston pin (20) and snap ring (19). Fit cylinder liner gasket on gear case. Offset piston ring butts by 120°...
  • Page 410 Group Subgroup 7001 Task Description Page Compress piston rings with pliers until band clamp can still just be displaced. Position cylinder liner over piston and press into place. Band clamp 000 589 20 61 00 Tighten hex screws (arrows). 25 Nm. Fit delivery valve diaphragm (9) on intermediate plate and insert washer (8) into recess (arrow) on diaphragm.
  • Page 411 Group Task Description Subgroup 7001 Page Fit intermediate plate (10) with new gasket (4) on cylinder head and tighten by hand. Fit suction valve diaphragm (11) and cylinder head gasket (12) with designation "Top" in direction of suction valve diaphragm on locking pins. Tighten hex screws for cylinder head (3) and hex screw (1) for intermediate plate to 30 Nm.
  • Page 412 Group Subgroup 7001 Task Description Page Tighten end cover (39) with new gasket on gear case to 25 Nm. Install gear case cover and seal (01-8000). Install coolant supply and return lines (arrows). Box wrench (open) 000 589 07 03 00 Install compressed air line (35) and intake line (36).
  • Page 413 Group Task Description Subgroup 7001 Page Remove hex screws (46) for compressor. Remove cylinder head (48) with intermediate plate. Remove cylinder liner (56). 20080/1 E 98-12...
  • Page 414 Group Subgroup 7001 Task Description Page Remove snap ring (61) for piston pin (63). Press out piston pin (63) and remove piston. Remove steering assist pump (37) and driver disc (38). Remove side cover (39). 20080/1 E 98-12...
  • Page 415 Group Task Description Subgroup 7001 Page Place locking device over connecting rod or crankshaft and tighten. Note The crankshaft must be rotated until the crankpin with connecting rod is facing upwards. Locking device 442 589 09 63 00 Unscrew hex screw from drive gear (73) with box wrench and remove drive gear (73) with hex screw.
  • Page 416 Group Subgroup 7001 Task Description Page Remove inner bearing flange (71) from gear case. Use a suitable mandrel to remove bearing bush from inner bearing flange. Use a suitable mandrel to remove bearing bush from outer bearing flange. 20080/1 E 98-12...
  • Page 417 Group Task Description Subgroup 7001 Page Remove gasket (55) and suction valve diaphragm (54) from intermediate plate or from cylinder head. 20080/1 E 98-12...
  • Page 418 Group Subgroup 7001 Task Description Page Unscrew hex screw (47) and remove cylinder head with gasket (49) from intermediate plate (53). 20080/1 E 98-12...
  • Page 419 Group Task Description Subgroup 7001 Page Remove hex nuts (50). Remove valve plates (51) and delivery valve diaphragms (52). Assembly Install bearing bush (67) in outer bearing flange (65) and recondition with a reamer. See Tolerances and Wear Limits List for specified values (13-7001).
  • Page 420 Group Subgroup 7001 Task Description Page Install bearing bush (70) in inner bearing flange (71) and recondition with a reamer. See Tolerances and Wear Limits List for specified values (13-7001). Note The groove (arrow) of the divided bearing bush must face upwards when installed.
  • Page 421 Group Task Description Subgroup 7001 Page Install bearing flange (65) by tightening hex screws (arrows) evenly. Again remove hex screws. Mount drive gear (73) with hex screw. Place locking device over connecting rod or crankshaft and tighten. Locking device 442 589 09 63 00. 20080/1 E 98-12...
  • Page 422 Group Subgroup 7001 Task Description Page Tighten hex screw of drive gear (270 Nm). Note This value corresponds to an actual torque of 360 Nm. Torque wrench (77), ratchet adapter (78) and box wrench (79) must be positioned in one line with respect to each other.
  • Page 423 Group Task Description Subgroup 7001 Page Offset piston ring butts by 120° (arrows). Compress piston rings with pliers until band clamp can still just be displaced. Position cylinder liner over piston and press into place. Band clamp 000 589 20 61 00. 20080/1 E 98-12...
  • Page 424 Group Subgroup 7001 Task Description Page Fit delivery valve diaphragms (52) and valve plates (51) and tighten hex nuts to 15 Nm. Note Delivery valve diaphragms (52) and valve plates (51) must snap into place. 20080/1 E 98-12...
  • Page 425 Group Task Description Subgroup 7001 Page Bolt cylinder head (48) and new gasket (49) with intermediate plate (53) and tighten by hand. 20080/1 E 98-12...
  • Page 426 Group Subgroup 7001 Task Description Page Fit suction valve diaphragm (54) and cylinder head gasket (55) with designation "Top" in direction of suction valve diaphragm (54) on locking pins. Place cylinder head (48) on cylinder liner. 20080/1 E 98-12...
  • Page 427 Group Task Description Subgroup 7001 Page Tighten hex screws (46) for compressor and hex screw (47) for intermediate plate to 30 Nm. Tighten end cover (39) with new gasket on gear case to 25 Nm. Install gear case cover and seal (01-8000).
  • Page 428 Group Subgroup 7001 Task Description Page 20080/1 E 98-12...
  • Page 429 Group Task Description Subgroup Page Exhaust Line 20080/1 E 98-12...
  • Page 430 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 431 Group Task Description Subgroup Page EXHAUST LINE Contents 14-3630 Exhaust lines removal and installation (V183T..2) 14-3630a Exhaust lines removal and installation (V183T..3) 20080/1 E 98-12...
  • Page 432 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 433 Group Task Description Subgroup 3630 Page 14-3630 Exhaust Lines (exhaust elbows) Removal and Installation (V183T..2) Exhaust lines, uncooled, 12V 183 1 Exhaust elbow, rear, left 10 Spring washer 2 Exhaust elbow, front, left 11 Screw 3 Exhaust elbow, centre, left 12 Gasket replace 4 Exhaust elbow, centre, right...
  • Page 434 Group Subgroup 3630 Task Description Page Exhaust lines, liquid-cooled, 12V 183 1 Exhaust line 8 Link 2 End cover 9 Sealing ring replace. 3 Plug, ventilation 10 Blank flange 4 Sealing ring replace. 11 Gasket replace. 5 Plug, drain 12 Screw 6 Gasket replace.
  • Page 435 Group Task Description Subgroup 3630 Page Exhaust elbow, liquid-cooled 1 Left elbow, installed with sealing paste, aux. material No. 50546 2 Right elbow, installed with sealing paste, aux. material No. 50546 3 Socket-head screw 80 Nm. 4 Socket-head screw 23 Nm. 5 Link 6 O-Ring replace.
  • Page 436 Group Subgroup 3630 Task Description Page Exhaust elbow between turbocharger and exhaust line 1 Elbow 2 Gasket 3 Link 4 O-Ring 5 Hex screw Note Remove exhaust pipework attachments according to engine version. Removal, installation Remove and install exhaust lines in accordance with sequence shown in illustration. 20080/0 E 97-02...
  • Page 437 Group Task Description Subgroup 3630a Page 14-3630a Exhaust Line Removal and Installation (v183 t..3) Exhaust lines 8V 183 T..3 1 Flange 15 Exhaust line (hot component) 31 Cover, free end, right 2 Socket-head screw MMN 384 16 O-ring 32 Cover, free end, left Lubricant: Engine oil 17 Hex screw 33 Washer...
  • Page 438 Group Subgroup 3630a Task Description Page Exhaust lines 12V 183 T..3 1 Flange 17 Hex screw 31 Washer 2 Socket-head screw MMN 384 18 Hex screw 32 Cover Lubricant: Engine oil 19 Clamp 33 Cover Pretighten: 30+3 Nm 20 Dowel pin 34 Hex screw Additional angle of rotation: 60+5°...
  • Page 439 Group Task Description Subgroup 3630a Page Carrier housing, left, 8V/12V 183 T..3 1 Carrier housing 17 Cover 2 Carrier housing upper section 18 Hex screw 3 Carrier housing lower section 19 Washer 4 Washer 20 Cover 5 Stud 21 Hex screw 6 Stud 22 Hex screw 7 Hex screw...
  • Page 440 Group Subgroup 3630a Task Description Page Carrier housing, right, 8V/12V 183 T..3 1 Carrier housing 11 Washer 2 Carrier housing upper section 12 Tab washer 3 Carrier housing lower section 13 Tab washer 4 O-ring 14 O-ring 5 Stud 15 Cover 6 Stud 16 Sealing ring 7 Hex screw...
  • Page 441 Group Task Description Subgroup 3630a Page Drain valve (waste gate), 8V/12V 183..3 1 Bracket 10 Washer 2 Hex screw 11 Hex screw 3 Washer 12 Clamp 4 Socket-head screw 13 Clamp 5 Drain valve DM 35 14 Washer 6 Air line, right 15 Hex screw 7 Air line, left 16 Hex nut...
  • Page 442 Group Subgroup 3630a Task Description Page Preparatory operations: Air filter removed (09-1030) Exhaust turbocharger removed (09-6030a Removal Remove exhaust lines in sequence shown in illustration. Installation Note: Install in accordance with arrangement drawing 506 002 27 14. Installation instructions: SB screws and MMN 384 screws can be used once only. Fit with assembly paste MTH 5128-Ultra-Therm, aux. material No.
  • Page 443 Group Task Description Subgroup Page Engine Electrical System 20080/1 E 98-12...
  • Page 444 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 445 Group Task Description Subgroup Page Engine Electrical System Contents 15-5030 Alternator (generator) removal and installation 15-7100 Starter removal and installation 20080/1 E 98-12...
  • Page 446 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 447 Group Task Description Subgroup 5030 Page 15-5030 alternator (generator) Removal and Installation (Example: ship version) Alternator 140 A 21 Washer 2 Belt pulley 22 Clamping element 3 Air intake cover 23 Clamping nut 4 Hex nut M5 24 Ball joint, fitted with thread-locking agent, aux. No. 40083 5 Grommet Tightening torque 74 + 6 Nm 6 Protective cap...
  • Page 448 Group Subgroup 5030 Task Description Page Removal/installation Disconnect battery negative terminal. Separate earth connection. Disconnect electrical wires from alternator. Release clamping screw (38) on alternator. Release V-belt with clamping nut (23) and remove via belt pulley. Installation instructions Replace and tension V-belt (13-1402). Tighten hex screw (38) for clamping element - tightening torque 40 + 4 Nm.
  • Page 449 Group Task Description Subgroup 7100 Page 15-7100 Starter Removal and Installation Preparatory operations: Disconnect battery negative terminal. 1 Hex nut 2 Spring washer 3 Earth wire 4 Hex nut 5 Spring washer 6 Electrical wire 7 Hex nut 8 Spring washer 9 Electrical wires 10 Hex nut 80 Nm...
  • Page 450 Group Subgroup 7100 Task Description Page Remove components in order of numbers and reinstall in reverse sequence. For cleaning work: With starter removed, clean with bearing flange facing down - i.e. hanging so that no moisture can penetrate the magnetic switch. With starter installed, do not clean with direct water jet.
  • Page 451 Group Task Description Subgroup Page Air Starting System 20080/1 E 98-12...
  • Page 452 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 453 Group Task Description Subgroup Page Air Starting System Contents 20080/1 E 98-12...
  • Page 454 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 455 Group Task Description Subgroup Page Engine Lubrication, Engine Oil Cooling 20080/1 E 98-12...
  • Page 456 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 457 Group Task Description Subgroup Page Engine Lubrication, Engine oil Cooling Contents 18-1600 Oil lines 18-1601 Engine oil system filling 18-3476 Oil filter element removal and installation 18-5471 Oil spray nozzle removal and installation 18-6023 Oil pump removal and installation 18-6068 Oil pump disassembly and assembly 18-6840 Oil cooler removal and installation (for hanging oil filter)
  • Page 458 Group Subgroup Task Description Page 20080/1 E 98-12...

  • Page 459: Oil Lines

    Group Task Description Subgroup 1600 Page 18-1600 Oil Lines Oil supply and return for exhaust turbocharger (8/12V 183 T..2) 1 Adapter 14 Hex screw 2 Sealing ring 15 Hex screw 3 Oil line 16 Elbow 4 T-piece 17 Elbow 5 Oil line, left 18 Washer 6 Oil line, right 19 Gasket...
  • Page 460 Group Subgroup 1600 Task Description Page Oil supply and return for exhaust turbocharger (8/12V 183 T..3) 1 Adapter 15 Hex screw 2 Sealing ring 16 Hex screw 3 Oil line 17 Flange 4 T-piece 18 O-ring 5 Oil line, left 19 Hex screw 6 Oil line, right 20 Washer...
  • Page 461 Group Task Description Subgroup 1600 Page Oil return from injection pump 1 Oil return line 2 Banjo screw 3 Sealing ring 20080/1 E 98-12...
  • Page 462 Group Subgroup 1600 Task Description Page Removal Remove oil lines Remove oil lines, connecting and fixture elements from engine as per overview. Remove sealing rings and gaskets. After removal, seal all connections with suitable plugs. Protect oil lines from damage. Inspection and repair Ensure that components are particularly clean.
  • Page 463 Group Task Description Subgroup 1600 Page Installation Note: Before installation, remove all blanking plugs. Caution! Compressed air is air which has been compressed under pressure. Risk of injury! Always wear protective goggles when blowing out or drying out with compressed air. The pressure must not exceed 3 bar.
  • Page 464 Group Subgroup 1600 Task Description Page 20080/1 E 98-12...

  • Page 465: Engine Oil System Filling

    Group Task Description Subgroup 1601 Page 18-1601 Engine Oil System Filling Special tools Scope of work Remove cylinder head cover of 1st and last cylinder (01-5014). Engine with hanging oil filter Remove hex socket screw from oil cooler cover. Screw in intermediate element (2) with reduction union (M18x1.5) (1) and connecting hose from oil filler tank 352 589 11 63 00.
  • Page 466 Group Subgroup 1601 Task Description Page Engine with standing oil filter Remove hex socket screw (3) at oil duct to oil filter housing. Screw reduction union (M20x1.5) to connecting hose from oil filler tank (5). Oil tank 352 589 11 63 00 Reduction union 442 589 12 63 00 Note:...
  • Page 467 Group Task Description Subgroup 1601 Page Unscrew connecting hose and reduction union or intermediate element and tighten hex socket screw with new gasket to 60 Nm. Install cylinder head cover (6) of 1st and last cylinder with new gaskets (7), tighten hex screws (8) to 25 Nm (01-5014).
  • Page 468 Group Subgroup 1601 Task Description Page Shut down engine after approx. 5 minutes. (Systems with long-life oil filter after approx. 10 minutes operation). Check engine oil level, top up if necessary (see operating instructions). 20080/1 E 98-12...

  • Page 469: 18-3476 Oil Filter Element Removal And Installation

    Group Task Description Subgroup 3476 Page 18-3476 Oil Filter Element Removal and Installation See Operating Instructions 20080/0 E 98-04...
  • Page 470 Group Subgroup 3476 Task Description Page 20080/0 E 98-04...
  • Page 471 Group Task Description Subgroup 5043 Page 18-5043 Pressure Relief Valve Removal and Installation Preparatory operations: Oil pan removed (01-7500). 1 Pressure relief valve Opening pressure at 6.5 ± 0.7 bar 2 Hex screw 35 Nm Removal and installation as shown in illustration. 20080/1 E 98-12...
  • Page 472 Group Subgroup 5043 Task Description Page 20080/1 E 98-12...
  • Page 473 Group Task Description Subgroup 5471 Page 18-5471 OIL SPRAY NOZZLE REMOVAL AND INSTALLATION Preparatory operations: Crankshaft removed (03-4352). Data Oil spray nozzle inner dia. 2 mm Special tools Removal/installation Remove oil spray nozzle (1) from crankcase. Installation instructions: The dowel pin of the oil spray nozzle (1) must engage in the crankcase bore.
  • Page 474 Group Subgroup 5471 Task Description Page Checking Secure oil spray nozzle (1) with banjo screw (2) on testing device. Note: Take care not to damage dowel pin. Testing device 403 589 01 23 00 With guide (3), check spraying direction of oil spray nozzle (1).

  • Page 475: Oil Pump Removal And Installation

    Group Task Description Subgroup 6023 Page 18-6023 Oil Pump Removal and Installation Preparatory operations: Pressure relief valve removed (18-5043). 1 Hex screw 35 Nm. 2 Hex screw 35 Nm. 3 Washer 4 Oil pump with oil extraction pipe Removal and installation Remove components in order of numbers and reinstall in reverse sequence.
  • Page 476 Group Subgroup 6023 Task Description Page 20080/1 E 98-12...

  • Page 477: Oil Pump Disassembly And Assembly

    Group Task Description Subgroup 6068 Page 18-6068 Oil Pump Disassembly and Assembly Preparatory operations: Oil pump removed (18-6020). 1 Hex screw 25 Nm, for 12V 183 35 Nm. 2 Cover 3 Gear, driven for 12V 183, 2 units. 4 Gear, driving 5 Oil pump housing 6 Drive gear 7 Gasket...
  • Page 478 Group Subgroup 6068 Task Description Page Special tools Disassembly, Assembly Remove intake pipe (9). Note: For 12V 183. Remove two intake pipes. Installation instructions Replace gasket. Tighten hex screws (8) to 25 Nm. Place dial gauge holder with dial gauge on oil pump. Place test prod of dial gauge under preload on oil pump shaft.
  • Page 479 Group Task Description Subgroup 6068 Page Remove housing cover (2). Installation instructions Tighten hex screws (1) to 25 Nm. For 12V 183, tighten hex screws (1) to 35 Nm. Remove driven gear (3) with shaft from housing. Note: For 12V 183, remove two driven gears. Remove drive shaft with driving gear from drive gear (6).
  • Page 480 Group Subgroup 6068 Task Description Page Installation instructions Heat drive gear (6) and press onto drive shaft (4) with a clearance of 0.5 mm to drive shaft (4). Remove driving gear (4) with drive shaft from housing. Assemble in reverse sequence. 20080/1 E 98-12...

  • Page 481: Oil Cooler Removal And Installation (For Hanging Oil Filter)

    Group Task Description Subgroup 6840 Page 18-6840 Oil Cooler Removal and Installation (for hanging oil filter) Preparatory operations: Engine coolant drained Oil filter element removed (see Operating Instructions) Gasket replace. Oil cooler, complete Sealing ring replace. Oil drain plug remove and drain oil, 50 Nm. Sealing ring replace.
  • Page 482 Group Subgroup 6840 Task Description Page Removal and installation Remove components in order of numbers and reinstall in reverse sequence. Fill engine oil system with engine oil, see 18-1601. Check and correct coolant level - see Operating Instructions. Oil priming and engine starting - see 18-1601. Switch off the engine, check the oil cooler for leaks.

  • Page 483: Oil Cooler Disassembly And Assembly (For Hanging Oil Filter)

    Group Task Description Subgroup 7109 Page 18-7109 Oil Cooler Disassembly and Assembly (for hanging oil filter) Preparatory operations: Oil cooler removed (18-6840) Plug 80 Nm. Sealing ring replace. Hex screw 70 Nm. Spring washer Cover Oil cooler Gaskets replace. Hex screw 25 Nm.
  • Page 484 Group Subgroup 7109 Task Description Page Disassembly, assembly Remove plug (1) for oil filling. Installation instructions Replace sealing ring (2) and tighten plug (1), 80 Nm. Remove hex screws (8) for oil cooler and remove oil cooler. Installation instructions Tighten hex screws (8) to 25 Nm. Fit graphitised side of gasket (7) in direction of oil cooler.
  • Page 485 Group Task Description Subgroup 7109a Page 18-7109a Oil Cooler Disassembly and Assembly (for flange-mounted standing oil filter) Oil cooler with oil filter 1 Filter bowl 2 Gasket, replace. 3 Screw M10x125 Tightening torque 50 Nm 4 Screw M10x60 Tightening torque 50 Nm 5 Spring washer B10 6 Oil filter bowl 7 Plug...
  • Page 486 Group Subgroup 7109a Task Description Page 19 Gasket, graphitised replace. 20 Screw M8x60 Tightening torque 25 Nm 21 Spring washer 22 Oil cooler 23 Screw M8x60 Tightening torque 25 Nm 24 Screw M8x35 Tightening torque 25 Nm 25 Spring washer 26 Gasket replace.
  • Page 487 Group Task Description Subgroup 7109a Page Removal, disassembly, assembly, installation Removal/disassembly Remove oil filter - see Operating Instructions. Remove oil filter head. Remove oil cooler cover with oil cooler. Remove oil cooler from oil cooler cover Remove oil cooler housing from crankcase. Remove bulkhead wall from oil cooler housing.
  • Page 488 Group Subgroup 7109a Task Description Page 20080/1 E 98-12...
  • Page 489 Group Task Description Subgroup Page Engine Cooling 20080/1 E 98-12...
  • Page 490 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 491 Group Task Description Subgroup Page Engine Cooling Contents 20-1000 Coolant lines (Ship version 8/12V 183 T..2 with top-mounted intercooler) 20-1000a Coolant lines (Ship version 8/12V 183 T..2 with compact intercooler) 20-1000b Coolant lines (Ship version 8/12V 183 T..3 with compact intercooler) 20-1000c Coolant connections with external cooling (Ship version 8/12V 183 T..2 with compact intercooler)
  • Page 492 Group Subgroup Task Description Page 20-2470 Coolant thermostat, removal, check and installation (Rail and genset version) 20-2470a Coolant thermostat, removal, check and installation (Ship version 8/12V 183 T..2 with top-mounted intercooler) 20-2470b Coolant thermostat, removal, check and installation (Ship version 8/12V 183 T..2 with compact intercooler) 20-2470c Coolant thermostat, removal, check and installation (Ship version 8/12V 183 T..3 with compact intercooler)

  • Page 493: Coolant Lines

    Group Task Description Subgroup 1000 Page 20-1000 Coolant Lines (ship version 8/12v 183 t..2 with top-mounted intercooler) Connecting lines between coolant distributor housing and intercooler Connection elbow, left Connection elbow, right O-ring replace. Hex screw M10x80 Hex screw M10x45 Plug-in pipe Plug-in pipe O-ring replace.
  • Page 494 Group Subgroup 1000 Task Description Page Connection between the exhaust turbochargers 1 Elbow 2 Gasket replace. 3 Hex screw M10x35 4 Washer 5 Pipe 6 Rubber sleeve replace. 7 Clamp 8 Union 9 Sealing ring replace. 10 Sealing cone 11 Nut 20080/1 E 98-12...
  • Page 495 Group Task Description Subgroup 1000 Page Vent lines 1 Cover 11 Gasket, replace. 2 Hex screw M8x55 12 Hose line 3 Sealing ring, replace 13 Sealing cone 4 Adapter 14 Nut 5 Hose line 15 Adapter 6 Sealing cone 16 Hose line 7 Nut 17 Sealing cone 8 Adapter...
  • Page 496 Group Subgroup 1000 Task Description Page 20080/1 E 98-12...

  • Page 497: 20-1000A Coolant Lines (Ship Version 8/12V 183 T

    Group Task Description Subgroup 1000a Page 20-1000a Coolant Lines (Ship version 8/12v 183 t..2 with compact intercooler) Connection between coolant thermostat, intercooler and turbocharger 1 Elbow, left side 2 Gasket replace. 3 Hex screw M10x60 4 Washer 5 Elbow 6 Plug 7 Sealing ring replace.
  • Page 498 Group Subgroup 1000a Task Description Page 17 Plug 18 Sealing ring replace. 19 Coolant line 20 Sealing ring replace. 21 Plug 22 Bracket 23 Hex screw M10x150 24 Washer 25 Pipe clamp half 26 Hex screw M8x80 27 Washer 28 Nut 29 Rubber sleeve replace.
  • Page 499 Group Task Description Subgroup 1000a Page Connection between coolant distributor housing and intercooler Elbow Gasket replace. Hex screw M8x50 Hex screw M8x80 Washer Pipeline Rubber sleeve replace. Clamp 20080/1 E 98-12...
  • Page 500 Group Subgroup 1000a Task Description Page Vent lines 1 Vent line 2 Threaded bush 3 Banjo screw 4 Sealing ring replace. 5 Washer 6 Hex screw M18x25 7 Clamp 8 Vent line 9 Threaded bush 10 Banjo screw 11 Sealing ring replace.

  • Page 501: 20-1000B Coolant Lines (Ship Version 8/12V 183 T

    Group Task Description Subgroup 1000b Page 20-1000b Coolant Lines (Ship version 8/12V 183 T..3 with compact intercooler) Connection between coolant distributor housing and intercooler 1 Elbow 2 Gasket replace. 3 Hex screw M8x50 4 Hex screw M8x80 5 Cover 6 Hex screw M8x28 7 Washer 8 Pipeline 9 Rubber sleeve...
  • Page 502 Group Subgroup 1000b Task Description Page Connection between intercooler and turbocharger 1 Elbow 2 O-ring replace. 3 Hex screw M8x105 4 Cover 5 O-ring replace. 6 Hex screw M8x25 7 Hex screw M8x80 8 Washer 9 Elbow 10 Gasket replace. 11 Hex screw M10x85 12 Washer 13 Rubber sleeve...
  • Page 503 Group Task Description Subgroup 1000b Page Vent lines 1 Flange 2 Gasket replace. 3 Hex screw M10x30 4 Washer 5 Vent line 6 Threaded bush 7 Banjo screw 8 Sealing ring replace. 9 Clamp 10 Hex screw M8x20 11 Washer 12 Vent line 13 Clamp 14 Clamp...
  • Page 504 Group Subgroup 1000b Task Description Page 23 Banjo screw 24 Sealing ring replace. 25 Vent line 26 T-piece 27 Adapter 28 Sealing ring replace. 29 Plug secured with thread-locking agent, aux. No. 40083. Coolant line installation and removal as shown in illustration - see also 20-10001. 20080/1 E 98-12...

  • Page 505: 20-1000C Coolant Connections With External Cooling

    Group Task Description Subgroup 1000c Page 20-1000c Coolant Connections with External Cooling (Ship version 8/12V 183 T..2 with compact intercooler) 1 Flange 2 O-ring 83x5 replace 3 Hex screw M12x80 4 Hex screw M20x1.5x80 5 Washer 6 Washer 7 Cover 8 Hex screw M8x55 9 Adapter 10 Sealing ring A26x31...
  • Page 506 Group Subgroup 1000c Task Description Page 20080/0 E 98-04...

  • Page 507: Coolant Lines, Removal, Check, Repair And Installation

    Group Task Description Subgroup 1001 Page 20-1001 Coolant Lines, Removal, Check, Repair, Reinstallation Remove coolant lines Note: Before removing lines, it is advisable to photograph the engine from all sides or attach metal tags to the lines and fixtures so that they can be reinstalled in their original positions. Remove lines as per overview drawings - see 20-1000 / 20-1000a / 20-1000b.
  • Page 508 Group Subgroup 1001 Task Description Page 20080/1 E 98-12...

  • Page 509: Degrease, Decalcify Cooling System, Check For Leaks

    Group Task Description Subgroup 1030 Page 20-1030 Degrease, decalcify cooling system, check for leaks Notice! Hot coolant: danger of scalding. Open coolant expansion tank end cover only when coolant temperature is under 90 °C. A. Degreasing, decalcifying and removing rust Suitable cleaning additives e.g.
  • Page 510 Group Subgroup 1030 Task Description Page Degreasing, removing rust Note: The cooling system must always be degreased before decalcifying even if there is no visible oil fouling. After rinsing for a second time during degreasing, fill the cooling system with a 10% solution (100g/l) of water and citric, tartaric or oxalic acid (available through regular chemical-trade outlets), whereby preference should be given to citric acid.

  • Page 511: Coolant Pump Removal And Installation (Rail And Genset Version)

    Group Task Description Subgroup 1290 Page 20-1290 Coolant Pump Removal and Installation (Rail and genset version) V-belts Tension, new 450 to 500 N, retension 300 to 400 N Measuring device 001 589 69 21 00. Coolant hose Coolant hose Hex screw 25 Nm.
  • Page 512 Group Subgroup 1290 Task Description Page 20080/1 E 98-12...

  • Page 513: 20-1290A Coolant Pump Removal And Installation (Ship Version 8/12V 183 T

    Group Task Description Subgroup 1290a Page 20-1290a Coolant Pump Removal and Installation (Ship version 8/12V 183 T..2/T..3) Water pump V-belt pulley Washer Hex screw M8x16 Tightening torque 25 Nm O-ring 130x3 replace. O-ring 158x3 replace Washer Hex screw M8x30 Removal and Installation Remove and install parts in illustrated sequence.
  • Page 514 Group Subgroup 1290a Task Description Page Disassembly, inspection, repair and assembly See Section 20-1401a. 20080/1 E 98-12...

  • Page 515: Raw Water Pump Removal And Installation (Ship Version 8/12V 183 T

    Group Task Description Subgroup 1390 Page 20-1390 Raw Water Pump Removal and Installation (Ship version 8/12V 183 T..2 with top-mounted intercooler) 1 Raw water pump 2 Wedge belt 3 Bracket 4 Hex screw M10x120 5 Nut 6 Washer 7 Washer 8 Swivel head secured with thread-locking agent, aux.
  • Page 516 Group Subgroup 1390 Task Description Page Disassembly, inspection, repair and assembly See Section 20-1402. 20080/1 E 98-12...

  • Page 517: 20-1390A Raw Water Pump Removal And Installation

    Group Task Description Subgroup 1390a Page 20-1390a Raw Water Pump Removal and Installation (Ship version 8/12V 183 T..2/T..3 with compact intercooler) 1 Raw water pump 2 Gasket replace. 3 Hex screw M10x60 4 Stud M10x30 5 Nut 6 Washer 7 Belt pulley 8 Hex screw M12x45 9 Washer 10 V-belts...
  • Page 518 Group Subgroup 1390a Task Description Page Removal and installation Remove and install parts in illustrated sequence. V-belt removal and installation - see Section 13-1001. Disassembly, inspection, repair and assembly See Section 20-1402a. 20080/1 E 98-12...

  • Page 519: Coolant Pump Disassembly And Assembly (Rail And Genset Version)

    Group Task Description Subgroup 1401 Page 20-1401 Coolant Pump, Disassembly and Assembly (Rail and genset version) Preparatory operations: Coolant pump removed (20-1290) Coolant thermostat (20-2470) removed 1 Hex screw 25 Nm 2 Washer 3 Housing cover 4 O-ring replace. 5 Coolant thermostat 6 Coolant pump housing 7 Bearing 8 Modular seal...
  • Page 520 Group Subgroup 1401 Task Description Page Dimensions - see Tolerances and Wear Limits List 20-1401. Special tools 20080/1 E 98-12...
  • Page 521 Group Task Description Subgroup 1401 Page Disassembly Remove belt pulley (13). Pull off flange (14) for belt pulley. Puller 000 589 65 33 00 Thrust pad 321 589 00 63 00 Remove snap ring (15). 20080/1 E 98-12...
  • Page 522 Group Subgroup 1401 Task Description Page Using a suitable thrust pad, force the bearing out of the impeller and housing. Remove modular seal. Assembly Using a suitable mandrel, press fit bearing in housing. Note: Press the bearing only on the bearing outer race (arrow).
  • Page 523 Group Task Description Subgroup 1401 Page Install snap ring (15). Heat flange (14) for belt pulley and press-fit flush on bearing. Mount new modular seal on the shaft. 20080/1 E 98-12...
  • Page 524 Group Subgroup 1401 Task Description Page Press in modular seal until it reaches coolant pump housing. Mandrel 352 589 08 15 00 Note: Check that modular seal is securely fitted. Mount coolant pump wheel (9). 20080/1 E 98-12...
  • Page 525 Group Task Description Subgroup 1401 Page Press-fit coolant pump wheel (9) until there is a gap of 0.6-1.0 mm to the bearing. Using a gauge (arrow), check the gap. Install belt pulley (13), 25 Nm. 20080/1 E 98-12...
  • Page 526 Group Subgroup 1401 Task Description Page 20080/1 E 98-12...

  • Page 527: 20-1401A Coolant Pump Disassembly, Check, Repair And Reinstallation (Ship Version 8/12V 183 T

    Group Task Description Subgroup 1401a Page 20-1401a Coolant Pump Disassembly, Check, Repair and Reinstallation (Ship version 8/12V 183 T..2/T..3) Preparatory operation: Coolant pump removed (20-1290a) Coolant pump housing Support for rotary seal with surface sealant MMN 377 D sealed with Loctite 573. Coolant pump bearing Snap ring Modular rotary seal...
  • Page 528 Group Subgroup 1401a Task Description Page Coolant pump housing Snap ring Pump bearing with shaft Rotary seal optional with item 5. Rotary seal optional with item 4. Impeller Flange = Control dimension 100 mm = Installation dimension, rotary seal, 11.9 ± 0.3 mm = Cleavage dimension, impeller, 0.6 + 0.4 mm For further dimensions - see Tolerances and Wear Limits List 20-1401a.
  • Page 529 Group Task Description Subgroup 1401a Page Disassembly Using the removal tool, pull off flange (7). Using circlip pliers, take the snap ring (2) out of the coolant pump housing. Using a suitable thrust pad, force the pump bearing and shaft (3) - assembly unit - out of the impeller and pump housing.
  • Page 530 Group Subgroup 1401a Task Description Page Assembly Installing coolant pump bearing Heat coolant pump housing (1) on hotplate. Using a suitable mandrel, press fit pump bearing (3) into housing. Note: Press the bearing only at the outer race! Using circlip pliers, insert the snap ring (2) in the groove in the coolant pump housing. Make sure that the snap ring is secure in the groove.
  • Page 531 Group Task Description Subgroup 1401a Page Assembly instruction for rotary seal, item 5: • Seal support in housing with surface sealant MMN 377 D - Loctite 573. • Using a suitable assembly tool, press-fit the rotary seal into the housing and press-fit dry onto the shaft; hold shaft end firmly in position.
  • Page 532 Group Subgroup 1401a Task Description Page 20080/1 E 98-12...

  • Page 533: 20-1402 Raw Water Pump Disassembly, Check, Repair And Reinstallation

    Group Task Description Subgroup 1402 Page 20-1402 Raw Water Pump Disassembly, Check, Repair and Reinstallation (Ship version 8/12V 183 T..2 with top-mounted intercooler) Preparatory operation: Raw water pump removed (20-1390) Raw water pump Belt pulley Tab washer replace. Hex nut 20080/1 E 98-12...
  • Page 534 Group Subgroup 1402 Task Description Page 1 Pump housing 2 Impeller 3 Intermediate element 4 Bearing housing 5 Drive shaft 6 Spacer bushing 7 Clamping nut Tightening torque 32 + 3 Nm Lubricant: Engine oil 8 Rotary seal replace. 9 Shaft seal replace.
  • Page 535 Group Task Description Subgroup 1402 Page Disassembly 20080/1 E 98-12...
  • Page 536 Check drive shaft for wear and damage. Smooth minor traces of wear and damage with an emery cloth. Metal-spray sealing surface as per MTU specifications as required. Check thread for ease of movement; rechase or fit thread insert as required.
  • Page 537 Group Task Description Subgroup 1402 Page Assembly Installing angular-contact ball bearing Clean all components. Heat angular-contact ball bearing (13) to 130 + 20 °C push onto the drive shaft (5) as far as the thrust collar. Notice! Risk of injury! Using circlip pliers, insert the inside snap ring (17) in the groove in the bearing housing (4).
  • Page 538 Group Subgroup 1402 Task Description Page Installing grooved ball bearing Push the spacer bush (6) onto the drive shaft. Heat grooved ball bearing (14) to 180 °C push onto the drive shaft (5) until it rests against the spacer bush. Notice! Risk of injury! Using circlip pliers, insert the snap ring (16) in the groove in the drive shaft (5).
  • Page 539 Group Task Description Subgroup 1402 Page Check axial gap Using a gauge, 0.5 mm, check axial gap 0.5 ± 0.2 at a minimum of three positions. Installing completely assembled unit in pump housing. Insert studs (20) in the pump housing (1). Insert O-ring (10) into the intermediate element (3).
  • Page 540 Group Subgroup 1402 Task Description Page 20080/1 E 98-12...

  • Page 541: 20-1402A Raw Water Pump Disassembly, Check, Repairand Reinstallation

    Group Task Description Subgroup 1402a Page 20-1402a Raw Water Pump Disassembly, Check, Repairand Reinstallation (Ship version 8/12V 183 T..2/T..3 with compact intercooler) Preparatory operation: Raw water pump removed (20-1390a) Pump housing Impeller Intermediate element Bearing housing Drive shaft Clamping nut Tightening torque 32 + 3 Nm Rotary seal replace.
  • Page 542 Group Subgroup 1402a Task Description Page 9 O-ring replace. 10 Sealing ring A18x22 replace. 11 Sealing ring A42x49 replace. 12 Angular-contact ball bearing 13 Grooved ball bearing 14 Adjusting shim 56x1 Axial gap setting. 14A Adjusting shim 56x0.5 Axial gap setting. 14B Adjusting shim 56.01 Axial gap setting.
  • Page 543 Group Task Description Subgroup 1402a Page Disassembly Removing complete unit from pump housing. Unscrew self-locking nuts (22). By knocking gently with a rubber mallet, release the complete unit from the pump housing (1) and remove it. 20080/1 E 98-12...
  • Page 544 Check drive shaft for wear and damage. Smooth minor traces of wear and damage with an emery cloth. Metal-spray sealing surface as per MTU specifications as required. Check thread for ease of movement; rechase or fit thread insert as required.
  • Page 545 Group Task Description Subgroup 1402a Page Assembly Installing grooved ball bearing Clean all components. Heat grooved ball bearing (13) to 180 °C and push onto the drive shaft (5) as far as the thrust collar. Notice! Risk of injury! Using circlip pliers, insert the snap ring (17) in the groove in the drive shaft (5). Ensure that the snap ring is correctly fitted in the groove! Installing drive shaft Insert drive shaft (5) with mounted bearing in the direction of the drive side in the bearing housing (4).
  • Page 546 Group Subgroup 1402a Task Description Page Mounting the impeller Mount the impeller (2) with installed sealing ring, free of oil and grease, on the taper of the drive shaft (5). Slightly oil clamping surface and clamping nut (6) thread. Fit clamping nut and tighten to specified torque. Tightening torque 35 + 3 Nm Mounting the assembled unit onto the assembly bearing.
  • Page 547 Group Task Description Subgroup 1402a Page Using circlip pliers, insert the outer snap ring (16) in the groove in the bearing housing (4). Tighten clamping nut (6) to specified torque. Tightening torque 35 + 3 Nm Using a gauge, check axial gap 0.5 ± 0.2 mm once again. Installing completely assembled unit in pump housing.
  • Page 548 Group Subgroup 1402a Task Description Page 20080/1 E 98-12...
  • Page 549 Group Task Description Subgroup 2470 Page 20-2470 Coolant Thermostat, Removal, Check and Installation (Rail and genset version) Hex screw 25 Nm. Washer Housing cover O-ring replace. Coolant thermostat install with vent opening (arrows) pointing upwards. Removal Remove hex screws and remove housing cover. Remove coolant thermostat from crankcase.
  • Page 550 Group Subgroup 2470 Task Description Page Check Secure thermostat on a wire in a container filled with water; thermostat must not contact container. Heat water with suitable heat source. At approx. 8 °C below opening temperature (depending on design), the heating speed must not exceed 1-2 °C per minute.
  • Page 551 Group Task Description Subgroup 2470a Page 20-2470a Coolant Thermostat, Removal, Check and Installation (Ship version 8/12V 183 T..2 with top-mounted intercooler) 1 Elbow, left 2 Gasket replace. 3 Washer 4 Hex screw M8x25 5 Hex screw M8x95 6 Plug-in pipe 7 O-ring 50x5 replace.
  • Page 552 Group Subgroup 2470a Task Description Page Removal Remove hex screws and remove thermostat housing. Remove thermostat elements from coolant distributor housing. Remove O-rings from coolant distributor housing. Check Secure thermostat insert on a wire in a container filled with water; thermostat insert must not contact container.
  • Page 553 Group Task Description Subgroup 2470a Page Installation Check sealing and mating faces. Grease new O-rings with petroleum jelly and insert in coolant distributor housing. Insert thermostat elements, with ventilation notches facing upwards, into coolant distributor housing. Install thermostat housing with hex screws. 20080/1 E 98-12...
  • Page 554 Group Subgroup 2470a Task Description Page 20080/1 E 98-12...
  • Page 555 Group Task Description Subgroup 2470b Page 20-2470b Coolant Thermostat, Removal, Check and Installation (Ship version 8/12V 183 T..2 with compact intercooler) 1 Elbow, left 2 Gasket replace. 3 Hex screw M8x30 4 Hex screw M8x95 5 Washer 6 Link 7 O-ring replace.
  • Page 556 Group Subgroup 2470b Task Description Page Removal Remove hex screws and remove thermostat housing. Remove thermostat elements from coolant distributor housing. Remove O-rings from coolant distributor housing. Check Secure thermostat insert on a wire in a container filled with water; thermostat insert must not contact container.
  • Page 557 Group Task Description Subgroup 2470b Page Continue to heat coolant to full-opening temperature. Full-opening temperature = 94 °C Thermostat insert must be completely open after approx. 6 to 8 minutes. Measure coolant thermostat stroke travel. Stroke must be 8.0 mm; if not, replace thermostat insert.
  • Page 558 Group Subgroup 2470b Task Description Page 20080/1 E 98-12...
  • Page 559 Group Task Description Subgroup 2470c Page 20-2470c Coolant Thermostat, Removal, Check and Installation (Ship version 8/12V 183 T..3 with compact intercooler) 1 Elbow, left 2 Plug M36x2 secured with thread-locking agent, aux. No. 40 083 3 O-ring 54x5 replace. 4 Hex screw M8x95 5 Washer 6 Thermostat housing 7 Thermostat insert...
  • Page 560 Group Subgroup 2470c Task Description Page Removal Remove hex screws and remove thermostat housing. Remove thermostat elements from coolant distributor housing. Remove O-rings from coolant distributor housing. Check Secure thermostat insert on a wire in a container filled with water; thermostat insert must not contact container.
  • Page 561 Group Task Description Subgroup 2470c Page Continue to heat coolant to full-opening temperature. Full-opening temperature = 75 °C Thermostat insert must be completely open after approx. 6 to 8 minutes. Measure stroke travel of thermostat insert. Stroke must be 8.0 mm; if not, replace thermostat insert.
  • Page 562 Group Subgroup 2470c Task Description Page 20080/1 E 98-12...
  • Page 563 Group Task Description Subgroup 2570 Page 20-2570 Coolant Cooler (Plate-Type Cooler) with "GEA" - Plates Removal, Check, Repair and Installation (Ship version 8V 183 T..2 with top-mounted intercooler) Plate-type cooler End plate (raw water) Second-last plate (fresh water) Intermediate plate (raw water) Intermediate plate (fresh water) Plate pair required 14 times.
  • Page 564 Group Subgroup 2570 Task Description Page Plate-type cooler installation components 1 Tab washer 2 Hex screw M12x180 lubricated with Ultratherm paste tighten diagonally and evenly. pretightening 25 + 3 Nm. further tightening 45 + 5 Nm, but not over block dimension, see sign 3 Cover plate 4 Grooved pin 2.5x5...
  • Page 565 Group Task Description Subgroup 2570 Page Removal To facilitate subsequent reassembly, apply a diagonal coloured mark to plate core. Cover plate removal (illustration, see page 2) Release tab washers (1). Unscrew hex screws (2) diagonally and evenly and remove with tab washers. Remove cover plate (3) from threaded pins.
  • Page 566 Group Subgroup 2570 Task Description Page Inspection and repair Distributor housing and cover plate cleaning Caution! When using chemical agents, always follow the manufacturer's instructions for use. Clean distributor housing and cover plate with cold cleaner and brush. To remove lime scale deposits, use lime scale remover which does not attach metal surfaces.
  • Page 567 Group Task Description Subgroup 2570 Page Coarse fouling (algae, wood, barnacles, crabs) Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner. Caution! Do not damage seals. Biological fouling and sludge (bacteria, protozoa) Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner.
  • Page 568 Group Subgroup 2570 Task Description Page Encrustations, scale and sediments Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner. Caution! Do not damage seals. Chemical cleaning with - Nitric acid* - Citric acid* - Phosphoric acid* - Sodium polyphosphates* * Concentration max.
  • Page 569 Group Task Description Subgroup 2570 Page Following solvents should not be used: - Ketones (e.g. acetone, methylethyketone, methyliso butyl ketone) - Esters (e.g. ethyl acetate, butyl acetate) - halogenised hydrocarbon (e.g. chlorothene, carbon tetrachlorides, feron) - Aromas (e.g. benzine, toluen) Clean profile gaskets of plates, check for damage.
  • Page 570 Group Subgroup 2570 Task Description Page Installation Raw water inlet elbow installation (illustration, see Page 2). Grease elbow (8), raw water inlet, and flange (15) with petroleum jelly and insert in coolant distributor housing. Secure flange (15) and elbow with screws (17) and washers (16) together. Screw plug (10) with new sealing ring (9) in elbow (8).
  • Page 571 Group Task Description Subgroup 2570a Page 20-2570a Coolant Cooler (Plate-Type Cooler) with "GEA" - Plates Removal, Check, Repair and Installation (Ship version 12V 183 T..2 with top-mounted intercooler) Plate-type cooler End plate (raw water) Second-last plate (fresh water) Intermediate plate (raw water) Intermediate plate (fresh water) Plate pair required 23 times.
  • Page 572 Group Subgroup 2570a Task Description Page Plate-type cooler installation components 1 Tab washer 2 Hex screw M12x260 lubricated with Ultratherm paste tighten diagonally and evenly. pretightening 25 + 3 Nm. further tightening 45 + 5 Nm, but not over block dimension, see sign 3 Cover plate 4 Grooved pin 2.5x5...
  • Page 573 Group Task Description Subgroup 2570a Page Removal To facilitate subsequent reassembly, apply a diagonal coloured mark to plate core. Cover plate removal (illustration, see page 2) Release tab washers (1), unscrew hex screw (2) diagonally and evenly and remove with tab washers. Remove cover plate (3) from threaded pins.
  • Page 574 Group Subgroup 2570a Task Description Page Inspection and repair Distributor housing and cover plate cleaning Caution! When using chemical agents, always follow the manufacturer's instructions for use. Clean distributor housing and cover plate with cold cleaner and brush. To remove lime scale deposits, use lime scale remover which does not attack metal surfaces.
  • Page 575 Group Task Description Subgroup 2570a Page Coarse fouling (algae, wood, barnacles, crabs) Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner. Caution! Do not damage seals. Biological fouling and sludge (bacteria, protozoa) Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner.
  • Page 576 Group Subgroup 2570a Task Description Page Encrustations, scale and sediments Carry out mechanical cleaning with soft brush and flowing water or high-pressure water cleaner. Caution! Do not damage seals. Chemical cleaning with - Nitric acid* - Citric acid* - Phosphoric acid* - Sodium polyphosphates* * Concentration max.
  • Page 577 Group Task Description Subgroup 2570a Page Clean profile gaskets of plates, check for damage. If gasket is damaged, replace respective channel plate. Repair work may involve the manufacturer replacing the rubber, if necessary. Check leak-off grooves (in rubber seals). In unpressed condition, leak-off groove must be approx. 8 mm wide. If leak-off groove is pressed together, it must be re-cut with a knife.
  • Page 578 Group Subgroup 2570a Task Description Page Installation Raw water inlet elbow installation (illustration, see Page 2). Grease elbow (8), raw water inlet, and flange (15) with petroleum jelly and insert in coolant distributor housing. Secure flange (15) and elbow with screws (17) and washers (16) together. Screw plug (10) with new sealing ring (9) in elbow (8).
  • Page 579 Group Task Description Subgroup 2570b Page 20-2570b Coolant Cooler (Plate-Type Cooler) with "SWEP" - Plates Removal, Check, Repair and Installation (Ship version 8/12V 183 T..2/T..3 with compact intercooler) 1 Elbow, raw water inlet 2 Sleeve 3 Hex screw M8x30 4 Washer 5 Hex screw M8x55 6 Washer 7 Hex screw M10x70...
  • Page 580 Group Subgroup 2570b Task Description Page 21 Intermediate plate (H), (fresh water) 22 Intermediate plate (raw water) 23 Plate pair (H) required for 8V 183 - 16 times, for 12V 183 - 23 times 24 End plate (H) 25 Hex screw M12x170 for 8V 183 M12x220...
  • Page 581 Group Task Description Subgroup 2570b Page Inspection and repair Clean all components. If necessary, use the surface crack-testing method with red penetrant dye or fluorescent penetrant dye to check channel plates for cracks; replace plates as necessary. Check gaskets of channel plates for damage, replace plates as necessary. Repair work may involve the manufacturer replacing the rubber, if necessary.
  • Page 582 Group Subgroup 2570b Task Description Page Chemical cleaning Caution! When using chemical substances, follow the manufacturer's instructions for use, safety instructions and waste disposal specifications. Note: Do not use the following solvents: Ketone (e.g. acetone, methyl ethyl ketone, methyl isobutyl ketone), ester (e.g. ethyl acetate, butyl acetate), halogenised hydrocarbon (e.g.
  • Page 583 Group Task Description Subgroup 2570b Page Distributor housing and cover plate cleaning and repair Clean components with cold cleaner and brush. Use only a soft brush to avoid damaging the plates and sealing faces. To remove lime scale deposits, use lime scale remover which does not attack metal surfaces. (e.g.
  • Page 584 Group Subgroup 2570b Task Description Page Channel plate installation Install guide pins (18) and coat with petroleum jelly. Fit initial plate (20) on guide pins. Install channel plates (21, 22), if possible in pairs (23), as per arrangement or markings on guide pins. Fit end plate (24) on guide pins.
  • Page 585 Group Task Description Subgroup 2670 Page 20-2670 Coolant Distributor Housing Removal and Installation (Ship version 8/12V 183 T..2 with top-mounted intercooler) 1 Distributor housing 2 Plug M18x1.5 3 Sealing ring A18x22 replace. 4 Plug M38x1.5 5 Sealing ring A38x44 replace. 6 Flange 7 Gasket replace.
  • Page 586 Group Subgroup 2670 Task Description Page Plug-in pipe Fixed in position. Sealing ring replace. Locking screw Removal and Installation as shown in illustration. Note: Before installing the coolant distributor housing, it is essential to install the coolant inlet and outlet elbows, shown in Subgroups 2570 and 2570a, Page 2. 20080/1 E 98-12...
  • Page 587 Group Task Description Subgroup 2670a Page 20-2670a Coolant Distributor Housing Removal and Installation (Ship version 8/12V 183 T..2 with compact intercooler) 1 Distributor housing 2 Plug M36x2 3 Plug M18x1.5 4 Sealing ring A18x22 replace. 5 Filler neck 6 Marker plate 7 Gasket replace.
  • Page 588 Group Subgroup 2670a Task Description Page 20080/1 E 98-12...
  • Page 589 Group Task Description Subgroup 2670b Page 20-2670b Coolant Distributor Housing Removal and Installation (Ship version 8/12V 183 T..3 with compact intercooler) 1 Distributor housing 2 Plug M18x1.5 3 Sealing ring A18x22 replace. 4 Filler neck 5 Marker plate 6 Gasket replace.
  • Page 590 Group Subgroup 2670b Task Description Page 20080/1 E 98-12...
  • Page 591 Group Task Description Subgroup Page Engine Suspension/Engine Mounting 20080/1 E 98-12...
  • Page 592 Group Subgroup Task Description Page 20080/1 E 98-12...
  • Page 595 Group Task Description Subgroup Page Special Installations 20080/1 E 98-12...
  • Page 596 Group Subgroup Task Description Page 20080/1 E 98-12...

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